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EB000000
YZF-R6
SERVICE MANUAL
1998 by Yamaha Motor Co., Ltd.
First edition, August 1998
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
EB001000
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. it is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EB002000
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EB003000
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(-s) appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
6
2
1
3
4
5
8
7
EB004000
1
2
GEN
INFO
SYMBOLS
SPEC
3
4
CHK
ADJ
ENG
5
6
COOL
CARB
7
8
CHAS
General information
Specifications
Periodic checks and adjustments
Engine
Cooling system
Carburetor(-s)
Chassis
Electrical system
Troubleshooting
Symbols 10 to 17 indicate the following.
10
10
11
12
13
14
15
16
17
TRBL
SHTG
11
12
13
14
15
16
17
18
19
20
24
1
2
3
4
5
6
7
8
9
ELEC
9
21
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
22
23
25
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication
points.
18
19
20
21
22
23
Engine oil
Gear oil
Molybdenum disulfide oil
Wheel bearing grease
Lithium soap base grease
Molybdenum disulfide grease
Symbols 24 to 25 in the exploded diagrams indicate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part
INDEX
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE OVERHAUL
COOLING SYSTEM
CARBURETORS
CHASSIS
ELECTRICAL
TROUBLESHOOTING
GEN
INFO
1
SPEC
2
CHK
ADJ
3
ENG
4
COOL
5
CARB
6
CHAS
7
ELEC
8
TRBL
SHTG
9
GEN
INFO
1
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . .
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . .
USING A DYNAMOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-2
1-2
1-3
1-3
1-3
1-3
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
1-5
1-5
1-6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
GEN
INFO
MOTORCYCLE IDENTIFICATION
GEN
INFO
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped
into the right side of the steering head pipe.
EB100020
MODEL CODE
The model code label 1 is affixed to the frame.
This information will be needed to order spare
parts.
1-1
IMPORTANT INFORMATION
GEN
INFO
EB102000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust, and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EB102010
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs.
Other brands may be similar in function and appearance, but inferior in quality.
EB102020
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals, and O-rings. All gasket surfaces, oil seal lips, and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
1-2
IMPORTANT INFORMATION
GEN
INFO
USING A DYNAMOMETER
The YZF-R6 has a carbon muffler that may
change color when exposed to high temperatures. Therefore, when using a dynamometer
always use a fan to cool the muffler.
EB102030
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock washer
tabs and the cotter pin ends along a flat of the
bolt or nut.
EB102040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the
oil seal lips with a light coat of lithium soap
base grease. Oil bearings liberally when
installing, if appropriate.
1 Oil seal
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
1 Bearing
EB102050
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always replace piston pin clips after one use.
When installing a circlip 1 , make sure that the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1-3
CHECKING THE CONNECTIONS
GEN
INFO
EB103000
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
lead
coupler
connector
2. Check:
lead
coupler
connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect several times.
3. Check:
all connections
Loose connection Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
4. Connect:
lead
coupler
connector
NOTE:
Make sure that all connections are tight.
5. Check:
continuity
(with the pocket tester)
Pocket tester
90890-03112
NOTE:
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps (1) to (3).
As a quick remedy, use a contact revitalizer
available at most part stores.
1-4
FEATURES
GEN
INFO
FEATURES
AIR INTAKE SYSTEM
System diagram
This system is designed to improve the power while riding a motorcycle at a high speed by increasing
the air intake efficiency by means of pressurizing the air filter case 2 where the air is taken in via the air
duct 1 from the air intake port located under the headlight.
The system also delivers air pressure from the air filter case to the carburetor side.
The air pressure is operated to the fuel level in the carburetor to supply the appropriate fuel to increase
the power.
The air chamber 3 is also installed between the air filter case and carburetor for delivery of stabilized
air pressure to the carburetor.
THERMOSTAT
Coolant flow is controlled by the thermostat of
which flow control valve 1 is newly developed
for avoiding quick temperature change.
(Refer to the graphs)
2 Notch groove
New thermostat
Temperature
Temperature
Former thermostat
Time
Time
1-5
GEN
INFO
FEATURES
Flow control operation
1) When valve is closed
The lip 1 seals the coolant.
2) When valve is set as low-lift
The 2nd lip 2 seals the coolant.
To reduce the water temperature change,
the coolant starts flowing through the notch
depending on its area at a section.
3) When the valve is set as middle-lift
The 3rd lip 3 seals the coolant.
The coolant flows through the notch depending on its area at b section.
This flow rate is larger than the case of 2).
4) When the valve is set as high-lift
In the same way as the regular thermostat
control, the coolant flows through clearance
c between the valve and flange.
1)
2)
3)
4)
IGNITION SYSTEM
1. DC CDI
1) Features
* Battery is used as the power source.
* Stabilized spark performance is provided in the range from a low speed to high speed since the
battery is used as the power source.
* Compact AC magneto design is possible since the source coil is unnecessary.
* Compact ignition coil design is possible since the condenser stores electricity.
Plug top ignition coil is equipped in which the plug cap and ignition coil are integrated.
* Stator coil can supply power even if the battery is running out.
2) Circuit diagram
1
2
3
4
CDI unit
Voltage converter
Condenser
Ignition coil
5
6
7
8
Spark plug
Ignition timing controller
Pickup coil
T. P. S.
9 Speed sensor
10 Battery
11 Rectifier/ regulator
12 AC magneto
1-6
13 Stator coil
FEATURES
2. Ignition coil
Compact and right weight design is provided
since the plug top ignition coil is equipped in
which the plug cap ignition coil are integrated.
High tension cord was cut an end to use and
ignition energy loss has become lower.
3. Spark plug
The 2-pole spark plug is applied to improve
the ignition quality and combustion efficiency.
1-7
GEN
INFO
SPECIAL TOOLS
GEN
INFO
EB104000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool name/Function
Illustration
Tool No.
Flywheel puller
90890-01362
Adapter
90890-04089
Flywheel puller
Adapter
This tool is used to remove the generator rotor.
Sheave holder
90890-01701
This tool is used to hold the generator rotor
when removing or installing the generator rotor bolt or pickup coil rotor bolt.
Piston pin puller
90890-01304
This tool is used to remove the piston pins.
Fuel level gauge
90890-01312
This tool is used to measure the fuel level in
the float chamber.
Radiator cap
tester
90890-01325
Adapter
90890-01352
Radiator cap tester
Adapter
These tools are used to check the cooling
system.
Steering nut wrench
90890-01403
This tool is used to loosen or tighten the steering stem ring nuts.
Damper rod holder
90890-01425
This tool is used to hold the damper rod assembly when loosening or tightening the
damper rod assembly bolt.
Pivot shaft wrench
90890-01471
This tool is used to loosen or tighten the pivot
adjust bolt and engine mount adjust bolt.
1-8
SPECIAL TOOLS
Tool No.
Tool name/Function
Oil filter wrench
90890-01426
This tool is needed to loosen or tighten the oil
filter cartridge.
Rod holder
90890-01434
Rod puller
90890-01437
Rod puller
attachment
90890-01436
This tool is used to support the damper adjusting rod.
Rod puller
Rod puller attachment
These tools are used to pull up the front fork
damper rod.
Fork spring compressor
90890-01441
This tool is used to disassemble or assemble
the front fork legs.
Fork seal driver Fork seal driver weight
90890-01376
Fork seal driver attachment
Fork seal driver
attachment
This tool is used to install the front fork’s oil
90890-01374
seal and dust seal.
Micrometer
90890-03008
This tool is used to measure the piston skirt
diameter.
Cylinder bore gauge (50~100mm)
90890-03017
Vacuum gauge
90890-03094
Valve gauge
attachment
90890-03060
Compression
gauge
90890-03081
Adapter
90890-04136
This gauge is used to measure cylinder bore.
Vacuum gauge
Vacuum gauge attachment
This gauge is used to synchronize the carburetors.
Compression gauge
Adapter
These tools are used to measure engine
compression.
Pocket tester
90890-03112
This tool is used to check the electrical system.
1-9
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Engine tachometer
90793-80009
This tool is used to check engine speed.
Timing light
90890-03141
Oil pressure
gauge
90890-03153
Adapter
90890-03139
This tool is used to check the ignition timing.
Oil pressure gauge
Adapter
These tools are used to measure engine oil
pressure.
Piston ring compressor
90890-04044
This tool is used to compress piston rings
when installing the cylinder.
Carburetor angle driver
90890-03158
Valve spring
compressor
90890-04019
Attachment
90890-04108
Middle driven shaft
bearing driver
90890-04058
Mechanical seal installer
90890-04078
This tool is used to turn the pilot screw when
adjusting the engine idling speed.
Valve spring compressor
Attachment
These tools are used to remove or install the
valve assemblies.
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the water pump
seal.
Clutch holding tool
90890-04086
This tool is used to hold the clutch boss
when removing or installing the clutch boss
nut.
Valve guide remover
90890-04111
This tool is used to remove or install the valve
guides.
1-10
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Valve guide installer
90890-04112
This tool is used to install the valve guides.
Valve guide reamer
90890-04113
This tool is used to rebore the new valve
guides.
Ignition checker
90890-06754
This tool is used to check the ignition system
components.
Yamaha bond No. 1215
90890-85505
This bond is used to seal two mating surfaces
(e.g., crankcase mating surfaces).
1-11
GEN
INFO
Illustration
GEN
INFO
SPEC
2
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-18
2-18
2-19
2-22
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-23
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES . . . . . 2-23
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES . . . . 2-24
OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
COOLANT FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Dimensions
Overall length
Standard
Limit
2025 mm (except for NOR, SWE, FIN, AUS NZL)
2075 mm (for NOR, SWE, FIN, AUS, NZL)
690 mm
1105 mm
820 mm
1380 mm
135 mm
3400 mm
188 kg
169 kg
Maximum load (total of cargo, rider, 375 kg
passenger, and accessories)
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine tipe
Displacement
Cylinder arrangement
Bore stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
Standard
Limit
Liquid-cooled, 4-stroke, DOHC
600 cm3
Forward-inclined parallel 4-cylinder
65.5 44.5 mm
12.4 : 1
1,250 1,350 r/min
24.0 kPa (0.24 kg/cm2)
1550 kPa (15.5 kgf/cm2) at 400 r/min
Regular gasoline
17 L
3.5 L
Wet sump
Temp.
SAE20W40SE or SAE10W30SE
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
3.5 L
2.5 L
2.7 L
80 kPa at 1300 r/min
(0.80 kgf/cm2 at 1300 r/min)
450 550 kPa (4.5 5.5 kgf/cm2)
2-2
ENGINE SPECIFICATIONS
Item
Oil filter
Oil filter type
Bypass valve opening pressure
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
Water pump
Water pump type
Reduction ratio
SPEC
Standard
Limit
Cartridge (paper)
80 120 kPa (0.8 1.2 kgf/cm2)
Trochoidal
0.03 0.09 mm
0.15 mm
0.03 0.08 mm
0.15 mm
2.15 L
110 140 kPa (1.10 1.40 kgf/cm2)
320 mm
258 mm
24 mm
0.44 L
Single-suction centrifugal pump
86/44 31/31 (1.955)
Starting system type
Electric starter
Spark plugs
Model (manufacturer) quantity
Spark plug gap
CR10EK/NGK 4
0.6 0.7 mm
Cylinder head
Max. warpage
0.05 mm
2-3
ENGINE SPECIFICATIONS
Item
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaftcap
clearance
Intake camshaft lobe dimensions
Standard
SPEC
Limit
Chain drive (right)
23.000 23.021 mm
22.967 22.980 mm
0.020 0.054 mm
0.08 mm
Measurement A
Measurement B
Measurement C
Exhaust camshaft lobe dimensions
33.05 33.15 mm
25.14 25.24 mm
7.81 8.01 mm
33.0 mm
25.09 mm
Measurement A
Measurement B
Measurement C
Max. camshaft runout
32.55 32.65 mm
25.07 25.17 mm
7.38 7.58 mm
32.50 mm
25.02 mm
0.06 mm
2-4
ENGINE SPECIFICATIONS
Item
Standard
Timing chain
Model/number of links
Tensioning system
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Head Diameter
Limit
RH2015/120
Automatic
0.11 0.20 mm
0.21 0.30 mm
Face Width
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
SPEC
Seat Width
Margin Thickness
24.9 25.1 mm
21.9 22.1 mm
1.14 1.98 mm
1.14 1.98 mm
0.9 1.1 mm
0.9 1.1 mm
1.6 mm
1.6 mm
0.6 0.8 mm
0.6 0.8 mm
0.5 mm
0.5 mm
3.975 3.990 mm
3.960 3.975 mm
3.950 mm
3.935 mm
4.000 4.012 mm
4.000 4.012 mm
4.042 mm
4.042 mm
0.010 0.037 mm
0.025 0.052 mm
0.08 mm
0.1 mm
0.04 mm
0.9 1.1 mm
0.9 1.1 mm
1.6 mm
1.6 mm
2-5
ENGINE SPECIFICATIONS
Item
Valve springs
Free length
Intake (inner)
(outer)
Exhaust
Installed length (valve closed)
Intake (inner)
(outer)
Exhaust
Compressed spring force
(installed)
Intake (inner)
(outer)
Exhaust
Spring tilt
Intake (inner)
(outer)
Exhaust
Winding direction (top view)
Intake
Exhaust
Cylinders
Cylinder arrangement
Bore stroke
Compression ratio
Bore
Max. taper
Max. out-of-round
SPEC
Standard
Limit
37.0 mm
38.4 mm
41.7 mm
35 mm
36.5 mm
39.5 mm
30.0 mm
32.5 mm
36.1 mm
SSS
69 79 N (7.0 8.0 kgf)
114 132 N (11.6 13.4 kgf)
160 184 N (16.3 18.7 kgf)
SSS
SSS
SSS
2.5_/1.6 mm
2.5_/1.7 mm
2.5_/1.8 mm
Clockwise
Clockwise
SSS
SSS
Forward-inclined, parallel 4-cylinder
65.5 45.5 mm
12.4 : 1
65.50 65.51 mm
SSS
SSS
SSS
SSS
SSS
SSS
0.05 mm
0.05 mm
2-6
SSS
SSS
ENGINE SPECIFICATIONS
Item
Pistons
Piston-to-cylinder clearance
Diameter D
SPEC
Standard
Limit
0.025 0.050 mm
65.460 65.475 mm
0.07 mm
4 mm
16.002 16.013 mm
0.35 0.65 mm
Intake side
0.5 mm
15.991 16.000 mm
0.002 0.022 mm
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
2nd ring
Barrel
0.80 2.45 mm
0.15 0.25 mm
0.030 0.065 mm
0.50 mm
0.115 mm
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
Oil ring
Taper
0.8 2.5 mm
0.40 0.50 mm
0.020 0.055 mm
0.85 mm
0.115 mm
1.5 2.3 mm
0.10 0.35 mm
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore
clearance
Piston rings
Top ring
Dimensions (B T)
End gap (installed)
2-7
0.072 mm
ENGINE SPECIFICATIONS
Item
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
SPEC
Standard
Limit
0.028 0.052 mm
1 = Blue 2 = Black 3 = Brown 4 = Green
Crankshaft
Width B
Max. runout C
Big end side clearance D
Crankshaft-journal-to-crankshaftjournal-bearing clearance
Bearing color code
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end
of the clutch lever)
Friction plates
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch plate
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
268.8 270.0 mm
0.160 0.262 mm
0.034 0.058 mm
0.03 mm
0 = White 1 = Blue
2 = Black 3 = Brown
4 = Green
Wet, multiple disc
Rack and pinion (pull rod type)
Cable operation
Left hand operation
10 15 mm
2.9 3.1 mm
8
2.8 mm
1.9 2.1 mm
7
0.1 mm
2.2 2.4 mm
1
0.1 mm
55 mm
6
54 mm
2-8
ENGINE SPECIFICATIONS
Item
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
SPEC
Standard
Limit
Constant mesh, 6-speed
Spur gear
86/44 (1.9545)
Chain drive
48/16 (3.000)
Left-foot operation
37/13 (2.846)
37/19 (1.947)
28/18 (1.555)
32/24 (1.333)
25/21 (1.190)
26/24 (1.083)
0.02 mm
0.02 mm
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
installed shift rod length
Cam drum
242 mm
0.05 mm
Air filter type
Dry element
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
5EB (MITSUBISHI)
15 20 kPa (0.15 0.2 kgf/cm2)
CVRD37 (MIKUNI) 4
6 8 mm
5EB00, 5EB200 (G), 5EB300 (F)
Carburetors 1 and 4: #152
Carburetors 2 and 3: #148
#110
N7RA
2.6
#110
0.9
#38
0.8
0.8
0.8
2
1.2
Carburetors
Model (manufacturer) quantity
Throttle cable free play (at the
flange of the throttle grip)
ID mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw turns out
Valve seat size
2-9
ENGINE SPECIFICATIONS
Item
Starter jet 1
Starter jet 2
Butterfly valve size
Fuel level (below the line on the
float chamber)
SPEC
Standard
#50
0.6
#110
17.5 18.5 mm
2-10
Limit
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 197 kg
High-speed riding
Min. tire tread depth
Standard
Limit
Diamond
24_
81 mm
SSS
SSS
SSS
Cast wheel
SSS
17 MT3.50
Aluminum
130 mm
SSS
SSS
SSS
SSS
SSS
1 mm
0.5 mm
Cast wheel
SSS
17 MT5.50
Aluminum
120 mm
SSS
SSS
SSS
SSS
SSS
1 mm
0.5 mm
Tubeless
120/60ZR17 (55W)
BRIDGESTON BT56F.E
DUNLOP
D207F.J
SSS
SSS
SSS
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
SSS
SSS
SSS
SSS
1.6 mm
2-11
CHASSIS SPECIFICATIONS
Item
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 197 kg
High-speed riding
Min. tire tread depth
Front brakes
Brake type
Operation
Recommended fluid
Brake discs
Diameter thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Rear brake
Brake type
Operation
Brake pedal position (from the top
of the brake pedal to the bottom of
the rider footrest bracket bolt center.)
Recommended fluid
Brake discs
Diameter thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
SPEC
Standard
Limit
Tubeless
180/55 ZR17 (73 W)
BRIDGESTON BT56R.E
DUNLOP
D207.N
250 kPa (2.5 kg/cm2, 2.5 bar)
290 kPa (2.9 kg/cm2, 2.9 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
1.6 mm
Dual-disc brake
Right-hand operation
DOT 4
298 5 mm
5.5 mm
4.5 mm
0.1 mm
0.5 mm
14 mm
30.2 mm and 27 mm
Single-disc brake
Right-foot operation
4.3 9.3 mm
DOT 4
220 5 mm
5 mm
4.5 mm
0.1 mm
0.8 mm
12.7 mm
27.0 mm and 22.2 mm
2-12
CHASSIS SPECIFICATION
Item
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the innertube,
with the inner tube fullycompressed,
and without thefork spring)
Damper adjusting rod locknut distance
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
SPEC
Standard
Limit
Telescopic fork
Coil spring/oil damper
130 mm
251.8 mm
125 mm
247.8 mm
7.5 N/mm (0.75 kgf/mm)
0 130 mm
No
246 mm
Suspension oil “01” or equivalent
476 cm3
107 mm
25 mm
8
5
1
11
6
1
12
6
1
2-13
CHASSIS SPECIFICATIONS
Item
Steering
Steering bearing type
SPEC
Standard
Limit
Angular ball bearings
Swingarm (link suspension)
Coil spring/gas-oil damper
60 mm
169.5 mm
159 mm
95.1 N/mm (9.51 kgf/mm)
0 60 mm
No
1,200 kPa (12 kgf/cm2)
1
4
9
25
9
1
13
7
1
Swingarm
Free play (at the end of the swingarm)
Radial
Axial
1 mm
1 mm
Drive chain
Model (manufacturer)
Link quantity
Drive chain slack
Maximum ten-link section
532ZLV KAI (DID)
116
40 50 mm
149 mm
Rear suspension
Suspension type
Rear shock absorber assemblytype
Rear shock absorber assemblytravel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air
pressure
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
2-14
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
Standard
Limit
System voltage
12 V
SSS
Ignition system
Ignition system type
Ignition timing
Advanced timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit model
(manufacturer)
C.D.I.
10_ BTDC at 1700 r/min
55_ BTDC at 5250 r/min
Throttle position sensor and electrical
248 372 Ω/Gy-B
F8T354 (MITSUBISHI)
SSS
SSS
SSS
SSS
SSS
SSS
F6T549 (MITSUBISHI)
6 mm
0.238 0.322 Ω
8.16 11.04 kΩ
SSS
SSS
SSS
SSS
4 6 kΩ
SSS
Charging system
System type
Model (manufacturer)
Nominal output
Stator coil resistance
AC magneto
F4T366 (MITSUBISHI)
14 V/320W at 5,000 r/min
0.27 0.33 Ω at 20_C
SSS
SSS
SSS
SSS
Voltage regulator
Regulator type
Model (manufacturer)
No-load regulated voltage
Semiconductor, short circuit type
SH650A-12 (SHINDENGEN)
14.1 14.9 V
SSS
SSS
SSS
Rectifier
Model
Rectifier capacity
Withstand voltage
SH650A-12
18 A
200 V
SSS
SSS
SSS
Battery
Battery type
Battery voltage/capacity
GT12B-4
12 V/10 AH
SSS
SSS
Headlight type
Halogen bulb
Indicator light type quantity
LED 5
Bulbs (voltage/wattage quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light
12 V 60 W/55 W 2
12 V 5 W 2
12 V 5 W/21 W 2
12 V 21 W 4
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Throttle position sensor standard
resistance
2-15
SSS
SSS
SSS
SSS
ELECTRICAL SPECIFICATIONS
Item
SPEC
Standard
Limit
12 V 5 W 2
12 V 1.4 W 2
Constant mesh
SM-14 (MITSUBA)
0.6 kW
10 mm
7.16 9.52 N (730 970 gf)
0.012 0.022 Ω
28 mm
0.7 mm
3.5 mm
27 mm
Starter relay
Model (manufacturer)
Amperage
Coil resistance
MS5F-631 (JIDECO)
180 A
4.18 4.62 Ω
Horn
Horn type
Model (manufacturer) quantity
Max. amperage
Plain
YF-12 (NIKKO) 1
3A
Flasher relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Full-transistor
FE246BH (DENSO)
No
75 95 cycles/min.
21 W 2 + 3.4 W
Oil level switch model (manufacturer)
4XV (DENSO)
Fuel sender
Model (manufacturer)
Resistance
1UF (NIPPON SEIKI)
0.7 1.1 kΩ GW-B
Sidestand relay
Model
Coil resistance
G8R-30Y-K
162 198 Ω
Fuel pump maximum amperage
1A
Fuel pump relay model (manufacturer)
Resistance
G8R-30Y-K (OMRON)
162 198 Ω
Radiator fan model (manufacturer)
4XV (TOYO RADIATOR)
Thermo switch model (manufacturer)
5EB (NIPPON THERMOSTAT)
Headlight relay (manufacturer)
Resistance
ACA12115 (MATSUSHITA)
72 88 Ω
License plate light
Meter light
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Commutator resistance
Commutator diameter
Mica undercut
2-16
ELECTRICAL SPECIFICATIONS
Item
Temperature sender
Model (manufacturer)
Resistance
Fuses (amperage quantity)
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Backup fuse (odometer)
SPEC
Standard
Limit
11H (NIPPON SEIKI)
50.6 64.2 Ω at 80_C
16.1 17.3 Ω at 120_C
SSS
SSS
30 A 1
20 A 1
20 A 1
15 A 1
7.5 A 1
7.5 A 1
SSS
SSS
SSS
SSS
SSS
SSS
2-17
CONVERSION TABLE/TIGHTENING TORQUES
SPEC
EB202001
EB201000
CONVERSION TABLE
TIGHTENING TORQUES
All specification data in this manual are
listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data
to IMPERIAL unit data.
Ex.
METRIC
MULTIPLIER
GENERAL TIGHTENING TORQUES
This chart specifies tightening torques for standard
fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or
assemblies are provided for each chapter of this
manual. To avoid warpage, tighten multi-fastener
assemblies in a crisscross pattern and progressive
stages until the specified tightening torque is
reached. Unless otherwise specified, tightening
torque specifications require clean, dry threads.
Components should be at room temperature.
IMPERIAL
**mm
0.03937
=
**in
2 mm
0.03937
=
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
Multiplier
Imperial unit
Tightening
torque
mSkg
mSkg
cmSkg
cmSkg
7.233
86.794
0.0723
0.8679
ftSlb
inSlb
ftSlb
inSlb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km / hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume /
Capacity
cc (cm3)
cc (cm
( 3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cuSin
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg / mm
kg / cm2
Centigrade
(_C)
55.997
14.2234
9 / 5 + 32
lb / in
psi (lb / in2)
Fahrenheit
(_F)
A: Width across flats
B: Thread diameter
2-18
A
(nut)
B
(bolt)
10 mm
12 mm
14 mm
18 mm
19 mm
22 mm
6 mm
8 mm
10 mm
12 mm
14 mm
16 mm
General tightening
torques
Nm
6
15
30
55
85
130
mSkg
0.6
1.5
3.0
5.5
8.5
13.0
ftSlb
4.3
11
22
40
61
94
TIGHTENING TORQUES
SPEC
ENGINE TIGHTENING TORQUES
Item
Fastener
Thread size
Q’ty
y
Tightening
torque
Nm
Spark plugs
Cylinder head
Cylinder head
Camshaft caps
Cylinder head cover
Oil passage check bolt
Cylinder head (exhaust pipe)
Connecting rod caps
Generator rotor
Pickup rotor
Cap bolt (timing chain tensioner)
Timing chain tensioner bolt
Camshaft sprocket
Oil pump
Oil cooler
Engine oil drain bolt
Oil pump assembly driven sprocket
cover
Oil pipe
Oil filter bolt
Oil filter cartridge
Exhaust pipes
Muffler clamp
Exhaust pipe emission check bolts
Exhaust pipe bracket
Crankcase
Crankcase
Crankcase
Generator rotor cover
Drive sprocket cover
–
Bolt
Bolt
Bolt
Bolt
Bolt
Stud bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
–
Bolt
M10
M10
M6
M6
M6
M8
M8
M7
M12
M8
M6
M6
M7
M6
M20
M14
M6
4
10
2
20
6
1
8
Bolt
Bolt
–
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
M6
M20
M20
M8
M8
M6
M8
M6
M6
M8
M6
M6
2
1
1
8
1
4
1
2
12
12
9
5
NOTE:
After tightening to 15 Nm (1.5mSkg), tighten another 90_
2-19
1
1
1
2
4
3
1
1
2
nSkgf
13
1.3
51
5.1
10
1.0
10
1.0
10
1.0
20
2.0
15
1.5
See NOTE
65
6.5
35
3.5
10
1.0
12
1.2
24
2.4
12
1.2
63
6.3
43
4.3
10
1,0
15
80
17
20
20
10
20
14
12
24
12
10
1.5
8.0
1.7
2.0
2.0
1.0
2.0
1.4
1.2
2.4
1.2
1.0
Remarks
TIGHTENING TORQUES
Item
Fastener
Thread
size
Q’ty
y
SPEC
Tightening
torque
Nm
mkgf
Clutch cover
Pickup coil rotor cover
Shift shaft cover
Breather plate 2
Starter clutch
Clutch boss
Bolt
Bolt
Bolt
–
Bolt
Nut
M6
M6
M6
M6
M8
M20
10
5
6
3
3
1
12
12
12
12
32
70
1.2
1.2
1.2
1.2
3.2
7.0
Clutch springs
Drive sprocket
Bolt
Nut
M6
M18
6
1
8
70
0.8
7.0
Main axle bearing housing
Shift bar stopper
Shift shaft spring stopper
Shift rod locknut
Screw
Bolt
Bolt
Nut
Oil level switch
Shift arm
Stator coil
Ignitor unit
Neutral switch
Pickup coil
Thermo unit
Thermo switch
Bolt
Bolt
Bolt
Bolt
Screw
Bolt
–
–
M6
M6
M8
M6
M8
M6
M6
M6
M6
M6
M5
PT1/8
M18 1.5
3
2
1
1
1
2
1
3
1
2
2
1
1
12
10
22
7
10
10
10
10
10
4.0
10
15
28
1.2
1.0
2.2
0.7
1.0
1.0
1.0
1.0
1.0
0.4
1.0
1.5
2.8
2-20
Remarks
Use a lock
washer.
Use a lock
washer.
TIGHTENING TORQUES
Crankcase tightening sequence:
2-21
SPEC
TIGHTENING TORQUES
SPEC
CHASSIS TIGHTENING TORQUES
Thread size
Item
Upper bracket pinch bolts
Steering stem nut
Handlebar pinch bolts
Lower ring nut
Lower bracket pinch bolts
Brake fluid reservoir cap stopper
Front brake hose union bolts
Front brake master cylinder
Engine mounting
Front mounting bolts
Rear mounting bolts
Pinch bolts
Button head bolt
Exhaust pipe bracket
Pivot shaft nut
Connecting arms
Relay arm and connecting arms
Relay arm
Rear shock absorber and relay arm
Fuel cock
Fuel sender and fuel tank
Coolant reservoir and radiator
Rider footrest bracket
Passenger footrest bracket
Rear master cylinder
Rear brake hose union bolts
Sidestand
Front wheel axle
Rear wheel axle nut
Front brake caliper and front fork
Rear brake caliper and bracket
Brake disc and wheel
Rear wheel sprocket and rear wheel drive hub
Brake caliper and bleed screw
Pinch bolt (front wheel axle)
Tightening
torque
Nm
mkgf
M8
M28
M8
M30
M8
M4
M10
M6
25
115
33
9
23
12
30
13
2.5
11.5
3.3
0.9
2.3
1.2
3.0
1.3
M12
M12
M10
M8
M6
M10
M8
M18
M10
M10
M10
M10
M6
M6
M6
M8
M8
M8
M10
M10
M18
M24
M10
M10
M6
M10
M8
M8
55
55
45
24
13
39
20
95
40
40
40
40
7
7
5
28
28
23
30
60
72
150
40
27
18
69
6
23
5.5
5.5
4.5
2.4
1.3
3.9
2.0
9.5
4.0
4.0
4.0
4.0
0.7
0.7
0.5
2.8
2.8
2.3
3.0
6.0
7.2
15.0
4.0
2.7
1.8
6.9
0.6
2.3
Remarks
See NOTE.
NOTE:
1. First, tighten the ring nut to approximately 17 Nm (1.7 mkg) with a torque wrench, then loosen the
ring nut completely.
2. Retighten the ring nut to specification.
2-22
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EB202000
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubricant
Lubrication point
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Connecting rod bolts and nuts
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil pump housing
Oil strainer
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum
Shift forks and shift fork guide bars
Shift shaft
Shift shaft boss
Engine mounting bolts (rear)
Cylinder head cover mating surface
Yamaha bond
No.1215
Crankcase mating surface
Yamaha bond
No.1215
Clutch cover (crankcase mating surface)
Yamaha bond
No.1215
Generator rotor cover (crankcase mating surface)
Yamaha bond
No.1215
Cylinder head cover
Yamaha bond
No.1215
2-23
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EB202010
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication
Lubricant
Steering bearings and bearing races (upper and lower)
Front wheel oil seal (right and left)
Rear wheel oil seal
Rear wheel drive hub oil seal
Rear wheel drive hub mating surface
Rear brake pedal
Sidestand pivoting point and metal-to-metal moving parts
Throttle grip inner surface
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Rear shock absorber assembly oil seal
Rear shock absorber assembly bearing
Rear shock absorber assembly spacer
Pivot shaft
Connecting arm bearing (left and right)
Spacer (relay arm and connecting arm)
Oil seal (relay arm and connecting arm)
2-24
OIL FLOW DIAGRAMS
OIL FLOW DIAGRAMS
1
2
3
4
5
6
Intake camshaft
Exhaust camshaft
Crankshaft
Oil pipe
Oil strainer
Oil pump
2-25
SPEC
OIL FLOW DIAGRAMS
1
2
3
4
Exhaust camshaft
Intake camshaft
Oil filter
Oil cooler
2-26
SPEC
OIL FLOW DIAGRAMS
1 Cylinder head
2 Crankshaft
2-27
SPEC
OIL FLOW DIAGRAMS
1 Main axle
2 Oil delivery pipe
3 driveaxle
2-28
SPEC
COOLANT FLOW DIAGRAMS
COOLANT FLOW DIAGRAMS
1 Radiator
2 Radiator fan
3 Oil cooler
2-29
SPEC
COOLANT FLOW DIAGRAMS
1
2
3
4
Thermostat housing
Thermostat
Radiator
Therm
2-30
SPEC
COOLANT FLOW DIAGRAMS
1
2
3
4
5
Radiator cap
Radiator
Oil cooler
Water jacket joint
Water pump
2-31
SPEC
COOLANT FLOW DIAGRAMS
1 Radiator
2 Radiator fan switch
3 Radiator fan
2-32
SPEC
CABLE ROUTING
SPEC
EB206000
CABLE ROUTING
1
2
3
4
5
6
7
Throttle cables
Front brake hose
Clutch cable
Starter cable
Left handlebar switch lead
Main switch lead
Right handlebar switch lead
A Install the headlight relays onto the headlight housing bridge.
B Route the headlight lead through the plastic guide.
C Route the right handlebar switch lead in front of the front fork inner
tube.
D Route the throttle cables between the brake hose and right handlebar
switch lead.
E Route the wire harness through under the left handlebar switch lead
and starter cable.
F Fasten the left handlebar switch lead to the front fork with a plastic
locking tie and cut the end of locking tie.
2-33
CABLE ROUTING
G Fasten the throttle cables and starter cable with a
band.
Locate the end of band to forward.
H Route the horn lead outside the throttle cables and
fasten it to the under bracket with a plastic locking
tie. Cut the end of locking tie. And then, route the
horn lead under the brake hose and clamp it to the
under cover.
2-34
SPEC
CABLE ROUTING
1
2
3
4
Fuel pump lead
Pickup coil lead
Clutch cable
Rear brake switch lead
A Route the ignition coil lead over the heat protector
plate.
B Position the face of steel clip up ward.
C Route the clutch cable through the guide on the
frame.
D Route the coolant hose under the heat protector
plate.
SPEC
E Route the clutch cable through the guide on the radiator.
F Fasten the clutch cable to the coolant hose protector with a plastic band.
G Fasten the rear brake switch lead to the footrest
bracket with a plastic locking tie and cut the end of
locking tie.
H Fasten the fuel pump lead and rear brake switch
lead with a plastic band on the fuel pump bracket.
2-35
CABLE ROUTING
1
2
3
4
5
6
7
8
9
A
AC magneto lead
Sidestand switch lead
Oil lever switch lead
Reservoir tank breather hose
Fuel tank breather hose
Fuel tank drain hose
Speed sensor lead
Neutral switch lead
Fuel pump lead
Route the throttle cable through inside of the radiator bracket and outside of the wireharness.
B Fasten the wireharness, radiator hose and fan motor lead with a plastic band.
SPEC
C Do not touch the wireharness with the throttle cable
pully.
Route the wireharness under the radiator hose.
D Route the wireharness through the slit of rear fender.
E Route the rear turn signal light leads (left and right)
through the hole of rear fender.
F Route the seat lock cable outside of the wireharness.
G Fasten the sidestand switch lead and oil level sensor lead with a band.
H Route the fuel tank drain hose, fuel tank breather
hose, reservoir tank breather hose, oil level switch
lead and sidestand switch lead through the guide
on the frame.
I Route the starter cable between the main switch
lead and left randlebar switch lead.
2-36
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Throttle cable
Handlebar switch lead (right)
Coolant reservoir breather hose
Carburetor idle adjusting cable
Pickup coil connector
Neutral switch connector
Rear brake switch connector
Handlebar switch (right) connectors
Main switch connectors
Throttle position sensor connector
Handlebar switch (left) connectors
Neutral switch lead
Fuel pump connector
Rear brake switch lead
Starter motor lead
16
17
18
19
20
21
22
23
24
25
SPEC
Battery negative (–) cable
Fuel sender connector
Coolant reservoir tank cap
Crankcase breather hose
Therm unit lead
Fan motor lead connector
Clutch cable
Handlebar switch lead (left)
Stater cable
Main switch lead
A To headlight lead
B Route the clutch cable through the guide.
2-37
CABLE ROUTING
SPEC
C Fasten the handlebar switch leads (left and right) H Route the starter motor lead under the wireharness.
and main switch lead with a band.
I Fasten the starter motor to the rear fender with a
D Route the ignition coil lead and handlebar switch
band.
leads (left and right) over the heat protection plate.
J Fasten the battery positive (+) cable and starter
E Route the reservoir tank hose, carburetor heater
motor cable with a plastic band.
hoses under the heat protector plate.
K Position the rear turn signal light connectors (left
F Fasten the neutral switch lead, right handlebar
and right) and taillight connector between the rear
switch lead, main switch lead, TPS lead, left hanfender and taillight bracket.
dlebar switch lead, pickup coil lead and throttle
L Install the seat lock cable to the frame bracket with
stop screw cable with a band.
protector side.
G Insert the projection of the band to the hole of the
frame and fasten the wireharness, neutral switch M Fasten the wireharness, oil level sensor lead,
ground lead and alarm leads (3 lines) with a band.
lead, handlebar switch leads (left and right), main
N Fasten the starter relay lead and battery negative
switch lead, throttle position sensor lead, rear
brake switch lead and pickup coil lead with them.
(–) lead to the wireharness with a plastic band.
O Fasten the battery negative (–) lead and wireharness with a plastic band.
2-38
CABLE ROUTING
P Insert the projection of the band (wireharness) into U
the hole of the frame.
V
Q 1: Speed sensor connector
2: AC magneto connector
3: Sidestand switch connector
W
4: Oil level switch connector
5: Meter ground lead
R Fasten the leads (above 1 – 5) and starter motor
lead with a steel band on the engine.
S Route the fuel tank breather hose and fuel tank
drain hose over the wireharness.
T Route the starter cable with slot of the heat protection plate.
2-39
SPEC
Route the starter cable and wireharness through
the guide of the heat protection plate.
Route the fan motor lead under the throttle cable
and then, fasten the fan motor lead and throttle
cable with a band.
To radiator fan motor
SPEC
CHK
ADJ
3
CHK
ADJ
CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . 3-1
RIDER AND PASSENGER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
COWLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
AIR FILTER CASE AND IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . 3-8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . .
CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . .
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CARBURETOR JOINTS . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11
3-11
3-16
3-18
3-20
3-22
3-23
3-24
3-26
3-27
3-29
3-30
3-31
3-32
3-32
3-33
3-33
3-34
3-35
3-35
3-36
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-39
3-39
3-39
3-41
3-42
CHK
ADJ
ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . . .
CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . .
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . .
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . .
3-42
3-43
3-43
3-45
3-45
3-47
3-47
3-50
3-51
3-53
3-55
3-57
3-58
3-58
3-58
3-58
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . .
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS . . . . . . . . . . . . . . . . . . . . . . .
3-59
3-59
3-64
3-66
3-67
INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS
CHK
ADJ
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EB301000
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
EVERY
No.
ITEM
CHECKS AND MAINTENANCE JOBS
1
*
Fuel line
Check fuel hoses for cracks or damage.
Replace if necessary.
2
*
Fuel filter
Check condition.
Replace if necessary.
Spark plugs
Check condition.
Clean, regap or replace if necessary.
Valves
Check valve clearance.
Adjust if necessary.
5
Air filter element
Clean or replace if necessary.
6
Clutch
Check operation.
Adjust or replace cable.
3
4
*
INITIAL
(1,000 km)
6,000 km or
6 months
(whichever
comes first)
12,000 km
or
12 months
(whichever
comes first)
√
√
√
√
√
√
Every 42,000 km or 42 months (whichever comes first)
√
√
√
√
√
7
*
Front brake
Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 3-2.)
Correct accordingly.
Replace brake pads if necessary.
√
√
√
8
*
Rear brake
Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 3-2.)
Correct accordingly.
Replace brake pads if necessary.
√
√
√
9
*
Wheels
Check balance, runout and for damage.
Rebalance or replace if necessary.
√
√
10 *
Tires
√
√
11 *
Wheel bearings
Check bearing for looseness or damage.
Replace if necessary.
√
√
12 *
Swingarm
Check swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
√
√
13
Drive chain
Check chain slack.
Adjust if necessary. Make sure that the rear wheel is
properly aligned.
Clean and lubricate.
Every 1,000 km and after washing the
motorcycle or riding in rain
14 *
Steering bearings
Check bearing play and steering for roughness.
Correct accordingly.
Lubricate with lithium soap base grease every
24,000 km or 24 months (whichever comes first).
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
3-1
√
√
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHK
ADJ
EVERY
No.
ITEM
CHECKS AND MAINTENANCE JOBS
INITIAL
(1,000 km)
6,000 km or
6 months
(whichever
comes first)
12,000 km
or
12 months
(whichever
comes first)
15 *
Chassis fasteners
Make sure that all nuts, bolts and screws are properly
tightened.
Tighten if necessary.
√
√
16
Sidestand
Check operation.
Lubricate and repair if necessary.
√
√
17 *
Sidestand switch
Check operation.
Replace if necessary.
√
√
18 *
Front fork
Check operation and for oil leakage.
Correct accordingly.
√
√
19 *
Rear shock absorber
assembly
Check operation and shock absorber for oil leakage.
Replace shock absorber assembly if necessary.
√
√
20 *
Rear suspension relay
arm and connecting
arm pivoting points
Check operation.
Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
√
√
21 *
Carburetors
Check engine idling speed, synchronization and
starter operation.
Adjust if necessary.
√
√
√
22
Engine oil
Check oil level and vehicle for oil leakage.
Correct if necessary.
Change. (Warm engine before draining.)
√
√
√
23
Engine oil filter cartridge
Replace.
√
Cooling system
Check coolant level and vehicle for coolant leakage.
Correct if necessary.
Change coolant every 24,000 km or 24 months (whichever comes first).
24 *
√
√
√
√
* Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.
NOTE:
The air filter element needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake system.
– Replace the brake fluid after disassembling the master cylinder or caliper cylinder.
– Check the brake fluid level and add fluid as required.
– Replace the master cylinder and caliper cylinder oil seals every two years.
– Replace the brake hoses every four years, or if cracked or damaged.
3-2
RIDER AND PASSENGER SEATS
CHK
ADJ
EB302000
RIDER AND PASSENGER SEATS
7Nm (0.7 mkg)
Order
1
2
Job/Part
Q’ty
Removing the rider and passenger
seats
Passenger seat
Rider seat
Remarks
Remove the parts in the order listed.
1
1
For installation, reverse the removal
procedure.
3-3
FUEL TANK
CHK
ADJ
FUEL TANK
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed
Refer to “SEATS”.
1
2
3
4
Removing the fuel tank
Rider seat
Bolt
Bolts
Fuel sender coupler
Fuel hose
1
2
1
1
5
6
7
Fuel tank overflow hose
Fuel tank breather hose
Fuel tank
1
1
1
Disconnect.
NOTE:
Before disconnecting the fuel hose, set
the fuel cock “OFF”.
For installation reverse the removal
procedure.
3-4
COWLINGS
CHK
ADJ
COWLINGS
5 Nm (0.5 mkg)
5 Nm (0.5 mkg)
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Remove the parts in the order listed
Refer to “SEATS”.
Removing the cowlings
Rider and passenger seats
Rear cowling
Bottom cowling (left)
Bottom cowling (right)
Front cowling inner panel (left)
Front cowling inner panel (right)
Side cowling inner panel (left)
Side cowling inner panel (right)
1
1
1
1
1
1
1
3-5
COWLINGS
CHK
ADJ
COWLINGS
5 Nm (0.5 mkg)
5 Nm (0.5 mkg)
Order
8
9
10
11
12
Job/Part
Q’ty
Remarks
1
1
1
2
1
Left side cowling
Right side cowling
Windshield
Rear view mirror
Front cowling
For installation, reverse the removal
procedure.
3-6
COWLINGS
CHK
ADJ
REMOVAL
1. Remove:
S rear cowling
S side cowlings
NOTE:
To remove the quick fastener, turn its center to
90_ with a screwdriver, then pull the fastener
out.
INSTALLATION
1. Install:
S side cowlings
S rear cowling
NOTE:
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the cowling and push the pin a
in with a screwdriver. Make sure that the pin is
flush with the fastener’s head.
3-7
AIR FILTER CASE AND IGNITION COILS
CHK
ADJ
AIR FILTER CASE AND IGNITION COILS
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Q’ty
Removing the air filter case and
ignition coils
Rider seat and fuel tank
Front cowling inner panel (left)
Front cowling inner panel (right)
Crankcase breather hose
Air vent hose
Hoses
Drain cup
Air filter case balance hose
Clamp screw
Bolt
Surge tank joint (left)
Surge tank joint (right)
Air filter case
Clamp
Quick fastener
Remarks
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK”.
Refer to “COWLINGS”.
1
1
2
1
2
4
1
1
1
1
2
2
3-8
Loosen.
AIR FILTER CASE AND IGNITION COILS
Order
13
14
15
Job/Part
Q’ty
Heat protector plate
Ignition coil coupler
Ignition coil
CHK
ADJ
Remarks
1
4
4
For installation, reverse the removal
procedure.
3-9
AIR FILTER CASE AND IGNITION COIL PLATE
CHK
ADJ
REMOVAL
1. Remove:
heat protector plate
NOTE:
To remove the quick fastener, push its center in
with a screwdriver, then pull the fastener out.
INSTALLATION
1. Install:
heat protector plate
NOTE:
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the rubber baffle and push the
pin a in with a screwdriver. Make sure that the
pin is flush with the fastener’s head.
3-10
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EB303001
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
Valve clearance adjustment should be made
on a cold engine, at room temperature.
When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
1. Remove:
rider seat
fuel tank
Refer to “SEATS” and “FUEL TANK”.
air filter case
heat protector plate
Refer to “AIR FILTER CASE AND IGNITION
COILS”.
bottom cowling
side cowlings
Refer to “COWLINGS”.
carburetor assembly
Refer to “CARBURETORS” in chapter 6.
radiator assembly
Refer to “RADIATOR” in chapter 5.
2. Remove:
ignition coils
spark plugs
cylinder head cover 1
cylinder head cover gasket
3. Remove:
pickup coil rotor cover 1
3-11
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
4. Measure:
S valve clearance
Out of specification Adjust
Valve clearance (cold)
Intake valve
0.11 0.20 mm
Exhaust valve
0.21 0.30 mm
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the
pickup coil rotor with the crankcase mating
surface b .
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
c. Measure the valve clearance with a thickness gauge 1 .
NOTE:
S If the valve clearance is incorrect, record the
measured reading.
S Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence
Cylinder #1 #2 #4 #3
A Front
d. To measure the valve clearances of the other
cylinders, starting with cylinder #1 at TDC,
turn the crankshaft counterclockwise as specified in the following table.
B Degrees that the crankshaft is turned counterclockwise
C Cylinder
D Combustion cycle
3-12
Cylinder #2
180_
Cylinder #4
360_
Cylinder #3
540_
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
5. Remove:
timing chain tensioner
timing chain guide (exhaust side)
camshaft cap
timing chain
(from the camshaft sprockets)
intake camshaft
exhaust camshaft
NOTE:
Refer to “CAMSHAFTS” in chapter 4.
When removing the timing chain from camshafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase.
6. Adjust:
valve clearance
a. Remove the valve lifter 1 and the valve pad
2.
NOTE:
Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
Make a note of the position of each valve lifter
1 and valve pad 2 so that they can be
installed in the correct place.
b. Select the proper valve pad from the following table.
Valve pad thickness range
Nos.
120 240
1.20 2.40 mm
Available valve
pads
25 thicknesses in
0.05 mm increments
NOTE:
The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.
Since valve pads of various sizes are originally
installed, the valve pad number must be
rounded in order to reach the closest equivalent to the original.
3-13
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
c. Round off the original valve pad number according to the following table.
Last digit
Rounded value
0 or 2
0
5
5
8
10
EXAMPLE:
Original valve pad number = 148 (thickness =
1.48 mm)
Rounded value = 150
d. Locate the rounded number of the original
valve pad and the measured valve clearance
in the valve pad selection table. The point
where the column and row intersect is the
new valve pad number.
NOTE:
The new valve pad number is only an approximation. The valve clearance must be measured
again and the above steps should be repeated if
the measurement is still incorrect.
e. Install the new valve pad 1 and the valve lifter 2 .
NOTE:
Lubricate the valve pad with molybdenum disulfide grease.
Lubricate the valve lifter with molybdenum disulfide oil.
The valve lifter must turn smoothly when rotated by hand.
Install the valve lifter and the valve pad in the
correct place.
f. Install the exhaust and intake camshafts,
timing chain and camshaft caps.
Camshaft cap bolt
10 Nm (1.0 mkg)
NOTE:
Refer to “CAMSHAFTS” in chapter 4.
Lubricate the camshaft lobes and camshaft
journals.
First, install the exhaust camshaft.
Align the camshaft marks with the camshaft
cap marks.
Turn the crankshaft counterclockwise several
full turns to seat the parts.
3-14
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
VALVE PAD SELECTION TABLE
INTAKE
B
A ORIGINAL VALVE PAD NUMBER
MEASURED
VALVE CLEARANCE
0.00 0.02
0.03 0.07
0.08 0.10
0.11 0.20
0.21 0.22
0.23 0.27
0.28 0.32
0.33 0.37
0.38 0.42
0.43 0.47
0.48 0.52
0.53 0.57
0.58 0.62
0.63 0.67
0.68 0.72
0.73 0.77
0.78 0.82
0.83 0.87
0.88 0.92
0.93 0.97
0.98 1.02
1.03 1.07
1.08 1.12
1.13 1.17
1.18 1.22
1.23 1.27
1.28 1.32
1.33 1.37
120 125 130 135
120
120 125
120 125 130
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
160
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120 125 130 135 140 145
120
120 125
120 125 130
120 125 130 135
120 125 130 135 140
150
125
130
135
140
145
155
130
135
140
145
150
160
135
140
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165 170 175 180 185 190 195 200 205 210 215
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
C STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220
175 180 185 190 195 200 205 210 215 220 225
180 185 190 195 200 205 210 215 220 225 230
185 190 195 200 205 210 215 220 225 230 235
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
Example:
230 235 240
Valve Clearance (cold)
235 240
240
0.11 0.20 mm
220
205
210
215
225
210
215
220
230
215
220
225
235 240
220 225
225 230
230 235
225 230 235 240
230 235 240
235 240
240
Rounded value 150
Measured valve clearance is 0.24 mm
Replace pad 150 with pad 160
Pad No. 150 = 1.50 mm
Pad No. 160 = 1.60 mm
Always install the valve pad with the
number facing down.
EXHAUST
B
A ORIGINAL VALVE PAD NUMBER
MEASURED
VALVE CLEARANCE
0.00 0.02
0.03 0.07
0.08 0.12
0.13 0.17
0.18 0.20
0.21 0.30
0.31 0.32
0.33 0.37
0.38 0.42
0.43 0.47
0.48 0.52
0.53 0.57
0.58 0.62
0.63 0.67
0.68 0.72
0.73 0.77
0.78 0.82
0.83 0.87
0.88 0.92
0.93 0.97
0.98 1.02
1.03 1.07
1.08 1.12
1.13 1.17
1.18 1.22
1.23 1.27
1.28 1.32
1.33 1.37
1.38 1.42
1.43 1.47
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165 170 175 180 185 190 195 200 205 210 215
140 145 150 155 160 165 170 175 180 185 190
145 150 155 160 165 170 175 180 185 190 195
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
C STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220
175 180 185 190 195 200 205 210 215 220 225
180 185 190 195 200 205 210 215 220 225 230
185 190 195 200 205 210 215 220 225 230 235
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
Example:
230 235 240
235 240
Valve Clearance (cold)
240
0.21 0.30 mm
220
195
200
205
210
215
225
200
205
210
215
220
230
205
210
215
220
225
235 240
210 215
215 220
220 225
225 230
230 235
225 230 235 240
230 235 240
235 240
240
Rounded value 175
Measured valve clearance is 0.35 mm
Replace pad 150 with pad 185
Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm
Always install the valve pad with the
number facing down.
3-15
ADJUSTING THE VALVE CLEARANCE/
SYNCHRONIZING THE CARBURETORS
CHK
ADJ
g. Measure the valve clearance again.
h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
7. Install:
all removed parts
NOTE:
For installation, reverse the removal procedure.
Note the following points.
8. Install:
timing chain guide (exhaust side)
timing chain tensioner
pickup coil rotor cover
cylinder head cover
spark plugs
ignition coils
Refer to “CAMSHAFTS” in chapter 4.
EB303010
SYNCHRONIZING THE CARBURETORS
NOTE:
Prior to synchronizing the carburetors, the valve
clearance and the engine idling speed should
be properly adjusted and the ignition timing
should be checked.
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
2. Remove:
rider seat
fuel tank
Refer to “SEATS” and “FUEL TANK”.
3-16
SYNCHRONIZING THE CARBURETORS
CHK
ADJ
3. Remove:
hose 1
4. Install:
vacuum gauge attachments
(into the bolt holes)
vacuum gauge 1
(onto the vacuum gauge attachments)
engine tachometer 2
(onto the ignition coil of cylinder #1)
Vacuum gauge
90890-03094
Vacuum gauge attachment
90890-03060
Engine tachometer
90793-80009
5. Start the engine and let it warm up for several
minutes.
6. Measure:
engine idling speed
Out of specification Adjust.
Refer to “ADJUSTING THE ENGINE IDLING SPEED”.
Engine idling speed
1,250 1,350 r/min
7. Adjust:
carburetor synchronization
a. Synchronize carburetor #1 to carburetor #2
by turning the synchronizing screw 1 in either direction until both gauges read the
same.
3-17
SYNCHRONIZING THE CARBURETORS/
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
NOTE:
After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
b. Synchronize carburetor #4 to carburetor #3
by turning the synchronizing screw 2 in either direction until both gauges read the
same.
c. Synchronize carburetor #2 to carburetor #3
by turning the synchronizing screw 3 in either direction until both gauges read the
same.
Vacuum pressure at engine
idling speed
24.0 kPa (0.24 kg/cm2)
NOTE:
The difference in vacuum pressure between
two carburetors should not exceed 1.33 kPa (10
mm Hg).
8. Measure:
engine idling speed
Out of specification Adjust.
9. Stop the engine and remove the measuring
equipment.
10. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle grip)
6 8 mm
EB303020
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed, the
carburetor synchronization should be adjusted
properly, the air filter element should be clean,
and the engine should have adequate compression.
1. Start the engine and let it warm up for several
minutes.
3-18
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
2. Remove:
air filter case
quick fasteners 1
band 2
Refer to “AIR FILTER CASE AND IGNITION
COILS”.
3. Install:
engine tachometer
(onto the ignition coil of cylinder #1)
Engine tachometer
90793-80009
4. Install:
air filter case
Refer to “AIR FILTER CASE AND IGNITION
COILS”.
5. Measure:
engine idling speed
Out of specification Adjust.
Engine idling speed
1,250 1,350 r/min
6. Adjust:
engine idling speed
a. Turn the pilot screw 1 in until it is lightly
seated.
b. Turn the pilot screw out the specified number
of turns.
Carburetor angle driver
90890-03158
Pilot screw setting
2 turns out
c. Turn the throttle stop screw 2 in direction a
or b until the specified engine idling speed is
obtained.
3-19
Direction a
Engine idling speed is
decreased.
Direction b
Engine idling speed is
increased.
ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
7. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle grip)
6 8 mm
EB303031
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed and carburetor synchronization should be adjusted properly.
1. Measure:
throttle cable free play a
Out of specification Adjust.
Throttle cable free play
(at the flange of the throttle grip)
6 8 mm
2. Remove:
rider seat
fuel tank
Refer to “SEATS” and “FUEL TANK”.
air filter case
heat protector plate
Refer to “AIR FILTER CASE AND IGNITION
COILS”.
3-20
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
3. Adjust:
throttle cable free play
NOTE:
When the throttle is opened, the accelerator
cable 1 is pulled.
Carburetor side
a. Loosen the locknut 2 on the decelerator
cable.
b. Turn the adjusting nut 3 in direction a or b
to take up any slack on the decelerator cable.
c. Loosen the locknut 4 on the accelerator
cable.
d. Turn the adjusting nut 5 in direction a or b
until the specified throttle cable free play is
obtained.
Direction a
Throttle cable free play
in increased.
Direction b
Throttle cable free play
is decreased.
e. Tighten the locknuts.
NOTE:
If the specified throttle cable free play cannot be
obtained on the carburetor side of the cable,
use the adjusting nut on the handlebar side.
Handlebar side
a. Loosen the locknut 6 .
b. Turn the adjusting nut 7 in direction c or d
until the specified throttle cable free play is
obtained.
Direction c
Throttle cable free play
is increased.
Direction d
Throttle cable free play
is decreased.
d. Tighten the locknut.
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
3-21
CHECKING THE SPARK PLUGS
CHK
ADJ
EB303040
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:
rider seat
fuel tank
Refer to “SEATS” and “FUEL TANK”.
air filter case
heat protector plate
Refer to “AIR FILTER CASE AND IGNITION
COILS”.
2. Disconnect:
Ignition coils
3. Remove:
spark plug
NOTE:
a. Remove the coupler.
b. Turn the coil counterdockwise. (5 to 6 turns
would be adequate.)
c. Pull out the coil upward.
Never pry the coupler with a screw driver.
d. Press the coil in the plug hole by hand as faras it will go.
e. Turn the coil clockwise and screw it in, 5 to 6
turns would be adequate.
f. Reins tall the coupler.
Do not strike on the coil with a hammer or the
like.
CAUTION:
Before removing the spark plugs, blow
away any dirt accumulated in the spark plug
wells with compressed air to prevent it from
falling into the cylinders.
4. Check:
spark plug type
Incorrect Change.
Spark plugs
type (manufacturer)
CR10EK (NGK)
3-22
CHECKING THE SPARK PLUGS/
CHECKING THE IGNITION TIMING
CHK
ADJ
5. Check:
electrodes 1
Damage/wear Replace the spark plug.
insulator 2
Abnormal color Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
spark plug gap a
(with a wire gauge)
Out of specification Regap.
Spark plug gap
0.6 0.7 mm
8. Install:
spark plug
13 Nm (1.3 mkg)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
EB303050
CHECKING THE IGNITION TIMING
NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure that all connections are tight and free
of corrosion.
1. Remove:
bottom cowling
Refer to “COWLINGS”.
rider seat
fuel tank
Refer to “SEATS” and “FUEL TANK”.
air filter case
Refer to “AIR FILTER CASE AND IGNITION
COILS”.
timing mark accessing screw 1
3-23
CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
2. Install:
timing light 1
engine tachometer
(onto the ignition coil of cylinder #1)
Timing light
90890-03141
Engine tachometer
90793-80009
3. Check:
ignition timing
a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed.
Engine idling speed
1,250 1,350 r/min
b. Check that the mark a is within the required
firing range b on the pickup coil rotor.
Incorrect firing range Check the ignition
system.
NOTE:
The ignition timing is not adjustable.
EB303060
MEASURING THE COMPRESSION PRESSURE
The following procedure applies to all of the cylinders.
NOTE:
Insufficient compression pressure will result in a
loss of performance.
1. Measure:
valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE”.
2. Start the engine, warm it up for several minutes, and then stop it.
3. Remove:
rider seat
fuel tank
Refer to “SEATS” and “FUEL TANK”.
air filter case
heat protector plate
ignition coils
Refer to “AIR FILTER CASE AND IGNITION
COILS”.
3-24
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
4. Remove:
spark plug
CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it
from falling into the cylinders.
5. Install:
compression gauge 1
Compression gauge
90890-03081
Adapter
90890-04136
6. Measure:
compression pressure
Out of specification Refer to steps (c) and
(d).
Compression pressure (at sea
level)
Minimum
1300 kPa (13.0 kg/cm2,
13.0 bar)
Standard
1550 kPa (15.5 kg/cm2,
15.5 bar)
Maximum
1600 kPa (16.0 kg/cm2,
16.0 bar)
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
WARNING
To prevent sparking, ground all spark plug
leads before cranking the engine.
NOTE:
The difference in compression pressure between cylinders should not exceed 100 kPa (1
kg/cm2, 1 bar).
3-25
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon deposits Eliminate.
d. If the compression pressure is below the
minimum specification, squirt a few drops of
oil into the cylinder and measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than
without oil
Piston wear or
damage Repair.
Same as without
oil
Piston ring(-s),
valve(-s), cylinder
head gasket or
piston possibly
defective Repair.
7. Install:
spark plug
13 Nm (1.3 mkg)
EB303070
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
2. Start the engine, let it idle for several minutes, and then stop it.
3. Check:
engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b .
Below the minimum level mark Add the
recommended engine oil to the proper level.
3-26
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
CHK
ADJ
Recommended oil
Refer to the chart for the engine oil
grade which is best suited for certain atmospheric temperatures.
API standard
SE or higher grade
(Non-Friction modified)
ACEA standard G4 or G5
CAUTION:
Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD c or higher and do
not use oils labeled “ENERGY CONSERVING II” d or higher.
Do not allow foreign materials to enter the
crankcase.
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check:
engine oil level
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
EB303081
CHANGING THE ENGINE OIL
1. Remove:
bottom cowling
Refer to “COWLINGS”.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Place a container under the engine oil drain
bolt.
4. Remove:
engine oil filler cap 1
engine oil drain bolt 2
(along with the washer)
5. Drain:
engine oil
(completely from the crankcase)
3-27
CHANGING THE ENGINE OIL
CHK
ADJ
6. If the oil filter cartridge is also to be replaced,
perform the following procedure.
a. Remove the oil filter cartridge 1 with an oil
filter wrench 2 .
Oil filter wrench
90890-01426
b. Lubricate the O-ring 3 of the new oil filter
cartridge with a thin coat of engine oil.
CAUTION:
Make sure theat the O-ring 3 is positioned
correctly in the groove of the oil filter cartridge.
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
Oil filter cartridge
17 Nm (1.7 mkg)
7. Check:
engine oil drain bolt washer
Damage Replace.
8. Install:
engine oil drain bolt
43 Nm (4.3 mkg)
9. Fill:
crankcase
(with the specified amount of the recommended engine oil)
Quantity
Total amount
3.5 L
Without oil filter cartridge replacement
2.5 L
With oil filter cartridge replacement
2.7 L
10. Install:
engine oil filler cap
11. Start the engine, warm it up for several minutes, and then turn it off.
12. Check:
engine
(for engine oil leaks)
3-28
CHANGING THE ENGINE OIL/
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
13. Check:
S engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
14. Install:
S bottom cowling
Refer to “COWLINGS”.
EB303090
MEASURING THE ENGINE OIL PRESSURE
1. Check:
S engine oil level
Below the minimum level mark Add the
recommended engine oil to the proper level.
2. Start the engine, warm it up for several minutes, and then turn it off.
CAUTION:
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
3. Remove:
S oil gallery bolt 1
WARNING
The engine, muffler and engine oil are extremely hot.
4. Install:
S oil pressure gauge 1
S adapter 2
Oil pressure gauge
90890-03153
Adapter
90890-03139
5. Measure:
S engine oil pressure
(at the following conditions)
Engine oil pressure
240 kpa (2.4 kg/cm2)
Engine speed
Approx. 6000 r/min
Engine oil temperature
96_C
3-29
MEASURING THE ENGINE OIL PRESSURE/
ADJUSTING THE CLUTCH CABLE FREE PLAY
CHK
ADJ
NOTE:
Regarding the oil pressure as its own data may
fluctuate depending on the oil temperature and
viscosity, the oil pressure may fluctuate when
measuring. The following data should be used
only as a reference when measuring the engine
oil pressure.
Out of specification Adjust.
Engine oil pressure
Below specification
Above specification
Possible cause
Faulty oil pump
Clogged oil filter
Leaking oil passapage
Broken or damaged
oil seal
Leaking oil passage
Faulty oil filter
Oil viscosity too high
6. Tighten the oil gallery bolt
20 Nm (2.0 mkg)
EB303100
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Measure:
clutch cable free play a
Out of specification Adjust.
Clutch cable free play (at the end
of the clutch lever)
10 15 mm
2. Adjust:
clutch cable free play
Handlebar side
a. Turn the adjusting bolt 1 in direction a or b
until the specified clutch cable free play is obtained.
Direction a
Clutch cable free play is increased.
Direction b
Clutch cable free play is decreased.
NOTE:
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
Engine side
a. Loosen the locknut 2 .
b. Turn the adjusting nut 3 in direction c or d
until the specified clutch cable free play is obtained.
Direction c
Clutch cable free play is increased.
Direction d
Clutch cable free play is decreased.
c. Tighten the locknut.
3-30
CLEANING THE AIR FILTER ELEMENT/
ADJUSTING THE CLUTCH CABLE FREE PLAY
CHK
ADJ
EB303130
CLEANING THE AIR FILTER ELEMENT
1. Remove:
fuel tank
Refer to “FUEL TANK”.
air filter case cover 1
air filter element
2. Clean:
air filter element
Use solvent to clean the air filter element. After cleaning the air filter element, remove the
solvent from the air filter element.
3. Apply the engine oil to the entire surface of
the filter and remove the excess oil. The air
filter should be wet but not dripping.
4. Check:
air filter element
Damage Replace.
5. Install:
air filter element
air filter case cover
CAUTION:
Never operate the engine without the air filter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor engine performance and possible overheating.
NOTE:
When installing the air filter element into the air
filter case cover, make sure that their sealing
surfaces are aligned to prevent any air leaks.
6. Install:
fuel tank
Refer to “FUEL TANK”.
3-31
CHECKING THE CARBURETOR JOINTS/
CHECKING THE FUEL HOSES AND FUEL FILTER/
CHK
ADJ
EB303171
CHECKING THE CARBURETOR JOINTS
The following procedure applies to all of the carburetor joints and intake manifolds.
1. Remove:
carburetor assembly
Refer to “CARBURETORS” in chapter 6.
2. Check:
carburetor joint 1
Cracks/damage Replace.
Refer to “CARBURETORS” in chapter 6.
3. Install:
carburetor assembly
Refer to “CARBURETORS” in chapter 6.
EB303181
CHECKING THE FUEL HOSES AND FUEL
FILTER
The following procedure applies to all of the fuel
hoses.
1. Remove:
fuel tank
Refer to “FUEL TANK”.
2. Check:
fuel hose 1
Cracks/damage Replace.
fuel filter 2
Contaminants/damage Replace.
NOTE:
Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident.
The arrow mark on the fuel filter must point towards the fuel pump as shown.
3. Install:
fuel tank
Refer to “FUEL TANK”.
3-32
CHECKING THE EXHAUST SYSTEM/
CLEANING THE AIR INTAKE SYSTEM
CHK
ADJ
EB303190
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
fuel tank
Refer to “FUEL TANK”.
2. Check:
crankcase breather hose 1
Cranks/damage Replace.
Loose connection Connect properly.
CAUTION:
Make sure that the crankcase breather hose
is routed correctly.
3. Install:
fuel tank
Refer to “FUEL TANK”.
EAS00092
CLEANING THE AIR INTAKE SYSTEM
The following procedure applies to both air intake system.
1. Remove:
side cowling inner covers
side cowlings
front cowling inner covers
front cowling
fuel tank
2. Loosen:
clamps
(on the inside of the front cowling)
3. Remove:
air intake system air ducts 1
4. Clean:
air intake system air ducts
a. Thoroughly flush out the air intake system air
ducts with clean water.
b. Hold the air intake system air ducts upside
down to allow the water to drain out.
c. Repeat the flushing steps until the excess
water is clear and free of debris.
d. Place the air intake system air ducts in an upright position to allow any remaining water to
drain out of the lower drain tube.
e. Keep the air intake system air ducts upright
to allow it to dry sufficiently.
5. Install:
air intake system air ducts
fuel tank
front cowling
front cowling inner covers
side cowlings
side cowlings inner covers
3-33
CHECKING THE CRANKCASE BREATHER HOSE/
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
2. Check:
crankcase breather hose 1
Cracks/damage Replace.
Loose connection Connect properly.
CAUTION:
Make sure that the crankcase breather hose
is routed correctly.
3. Install:
fuel tank
Refer to “FUEL TANK”.
EB303200
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the exhaust pipes and gaskets.
1. Remove:
radiator assembly
Refer to “RADIATOR” in chapter 5.
2. Check:
exhaust pipe 1
muffler 2
Cracks/damage Replace.
gasket 3
Exhaust gas leaks Replace.
3. Measure:
tightening torque
Exhaust pipe nut 4
20 Nm (2.0 mkg)
Muffler clamp bolt 5
20 Nm (2.0 mkg)
Exhaust pipe bolt 6
20 Nm (2.0 mkg)
Muffler bolt 7
38 Nm (3.8 mkg)
4. Install:
radiator assembly
Refer to “RADIATOR” in chapter 5.
3-34
CHECKING THE COOLANT LEVEL/
CHECKING THE COOLING SYSTEM
CHK
ADJ
EB303220
CHECKING THE COOLANT LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
2. Check:
coolant level
The coolant level should be between the
maximum level mark a and minimum level
marks b .
Below the minimum level mark Add the
recommended coolant to the proper level.
CAUTION:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check and correct
the antifreeze concentration of the coolant.
Use only distilled water. Soft water may be
used if distilled water is not available.
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Check:
coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
EB303230
CHECKING THE COOLING SYSTEM
1. Remove:
bottom cowling
side cowlings
Refer to “COWLINGS”.
2. Check:
radiator 1
radiator inlet hose 2
radiator outlet hose 3
oil cooler 4
oil cooler inlet hose 5
oil cooler outlet hose 6
water pump outlet hose 7
Cracks/damage Replace.
Refer to “COOLING SYSTEM” in chapter 5.
3. Install:
side cowlings
bottom cowling
Refer to “Cowlings”.
3-35
CHANGING THE COOLANT
CHK
ADJ
EB303240
CHANGING THE COOLANT
1. Remove:
bottom cowling
left side cowling
Refer to “COWLINGS”.
reservoir hose clamps 1
2. Remove:
coolant reservoir bolts 2
coolant reservoir cap 3
NOTE:
When draining the coolant from the coolant reservoir, be sure to tilt the reservoir so that coolant
cannot flow through the coolant reservoir
breather hose 4 .
3. Drain:
coolant
(from the coolant reservoir)
4. Install:
coolant reservoir bolts
reservoir cover
5. Remove:
radiator cap 1
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam
may be blown out, which could cause serious injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counterclockwise toward the detent to allow any
residual pressure to escape. When the hissing sound has stopped, turn the radiator
cap counterclockwise while pressing down
on it and then remove it.
3-36
CHANGING THE COOLANT
CHK
ADJ
6. Remove:
coolant drain bolt 1
(along with the copper washer)
7. Drain:
coolant
8. Check:
coper washer 1
coolant drain bolt 2
Damage Replace
9. Install:
coolant drain bolt
7 Nm (0.7 mkg)
10. Fill:
cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze: water)
Quantity
Total amount
2.15 L
Coolant reservoir capacity
0.44 L
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
If coolant splashes on your clothes, quickly wash it away with water and then with
soap and water.
If coolant is swallowed, induce vomiting
and get immediate medical attention.
3-37
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant.
Use only distilled water. However, soft water may be used if distilled water is not
available.
If coolant comes into contact with painted
surfaces, immediately wash them with water.
Do not mix different types of antifreeze.
11. Install:
radiator cap
12. Fill:
coolant reservoir
(with the recommended coolant to the maximum level mark a )
13. Install:
coolant reservoir cap
14. Start the engine, warm it up for several minutes, and then turn it off.
15. Check:
coolant level
Refer to “CHECKING THE COOLANT LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
16. Install:
left side cowling
bottom cowling
Refer to “COWLINGS”.
3-38
ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
CHK
ADJ
EB304001
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
brake lever position
(distance a from the throttle grip to the
brake lever)
a. While pushing the brake lever forward, turn
the adjusting dial 1 until the brake lever is in
the desired position.
NOTE:
Be sure to align the setting on the adjusting dial
with the arrow mark 2 on the brake lever holder.
Position #1
Distance a is the largest.
Position #5
Distance a is the smallest.
WARNING
After adjusting the brake lever position,
make sure that the pin on the brake lever
holder is firmly inserted in the hole in the adjusting dial.
EB304010
ADJUSTING THE REAR BRAKE
1. Measure:
brake pedal position
(distance a from the top of the brake pedal
to the bottom of the rider footrest bracket bolt
center)
Out of specification Adjust.
Brake pedal position (from the
top of the brake pedal to the
bottom of the rider footrest
bracket bolt center)
4.3 9.3 mm
b :
3-39
11mm
ADJUSTING THE REAR BRAKE
CHK
ADJ
2. Adjust:
brake pedal position
a. Loosen the locknut 1 .
b. Turn the adjusting bolt 2 in direction a or b
until the specified brake pedal position is obtained.
Direction a
Brake pedal is raised.
Direction b
Brake pedal is lowered.
WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt c is
visible through the hole d .
c. Tighten the locknut 1 to specification.
Locknut
16 Nm (1.6 mkg)
WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident.
Therefore, check and, if necessary, bleed
the brake system.
CAUTION:
After adjusting the brake pedal position,
make sure that there is no brake drag.
3. Adjust:
rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
3-40
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
EB304020
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
2. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
A
Recommended brake fluid
DOT 4
A Front brake
B Rear brake
WARNING
Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the brake
fluid reservoir is horizontal.
3-41
CHECKING THE BRAKE PADS/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
CHK
ADJ
EB304032
A
CHECKING THE BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
front brake pad
rear brake pad
Brake pad wear limit a
Wear limit reached Replace the brake
pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
B
Brake pad wear limit
a 0.5 mm b 0.8 mm
A Front brake
B Rear brake
EB304050
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
The rear brake light switch is operated by
movement of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.
1. Check:
rear brake light operation timing
Incorrect Adjust.
2. Adjust:
rear brake light operation timing
a. Hold the main body 1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper time.
3-42
Direction a
Brake light comes on
sooner.
Direction b
Brake light comes on
later.
CHECKING THE BRAKE HOSES/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EB304062
CHECKING THE BRAKE HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
brake hose 1
Cracks/damage/wear Replace.
2. Check:
brake hose clamp
Loose Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:
brake hose
Brake fluid leakage Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
EB304072
BLEEDING THE HYDRAULIC BRAKE SYSTEM
WARNING
Bleed the hydraulic brake system whenever:
the brake system was disassembled,
a brake hose was loosened, disconnected
or replaced,
the brake fluid level is very low,
brake operation is faulty.
NOTE:
Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.
When bleeding the hydraulic brake system,
make sure that there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the hydraulic brake system, considerably lengthening the
bleeding procedure.
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
3-43
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
5. Bleed:
hydraulic brake system
A
a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2 .
A Front brake
B Rear brake
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position.
g. Loosen the bleed screw.
B
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 mkg)
k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
3-44
ADJUSTING THE SHIFT PEDAL/
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
EB304081
ADJUSTING THE SHIFT PEDAL
NOTE:
The shift pedal position is determined by the
installed.
1. Measure:
incorrect Adjust.
The top of sift pedal should be
aligned with the lower part of the
bracket. (from the horizontal view)
2. Adjust:
installed shift rod length
a. Loosen both locknuts 1 .
b. Turn the shift rod 2 in direction b or c to
obtain the correct shift pedal position.
Direction b
Installed shift rod length
increases.
Direction c
Installed shift rod length
decreases.
c. Tighten both locknuts.
d. Make sure that the installed shift rod length is
within specification.
EB304092
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at the
tightest point on the chain.
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swingarm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
3-45
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
2. Rotate the rear wheel several times and
check the drive chain to locate its tightest
point.
3. Measure:
drive chain slack a
Out of specification Adjust.
Drive chain slack
40 50 mm
4. Adjust:
drive chain slack
a. Loosen the wheel axle nut 1 .
b. Loosen both locknuts 2 .
c. Turn both adjusting bolts 3 in direction a or
b until the specified drive chain slack is obtained.
Direction a
Drive chain slack is
reduced.
Direction b
Drive chain slack is
increased.
NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.
d. Tighten both locknuts to specification.
Locknut
16 Nm (1.6 mkg)
e. Tighten the wheel axle nut to specification.
Wheel axle nut
150 Nm (15.0 mkg)
3-46
LUBRICATING THE DRIVE CHAIN/
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
EB304100
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained properly, it will wear out rapidly. Therefore, the drive
chain should be serviced, especially when the
motorcycle is used in dusty areas. This motorcycle has a drive chain with small rubber Orings between each side plate. Steam cleaning,
high-pressure washing, certain solvents, and
the use of a coarse brush can damage these Orings. Therefore, use only kerosine to clean the
drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. Do not
use any other lubricants on the drive chain since
they may contain solvents that could damage
the O-rings.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
EB304130
CHECKING AND ADJUSTING THE STEERING HEAD
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Check:
steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Looseness/binding Adjust the steering
head.
3-47
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
3. Remove:
upper bracket bolts 1
front brake fluid reservoir bolt 2
4. Loosen:
upper bracket pinch bolts 1
handlebar pinch bolts 2
washer 3
5. Remove:
handlebars
(from the upper bracket)
6. Remove:
steering stem nut 1
washer 2
upper bracket 3
7. Adjust:
steering head
a. Remove the lock washer 1 , the upper ring
nut 2 , and the washer 3 .
b. Loosen the lower ring nut 4 and then tighten
it to specification with a ring nut wrench 5 .
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01403
Lower ring nut (initial tightening
torque)
17 Nm (1.7 mkg)
3-48
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
c. Loosen the lower ring nut completely, then
tighten it to specification.
WARNING
Do not overtighten the lower ring nut.
Lower ring nut (final tightening
torque)
9 Nm (0.9 mkg)
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chapter 7.
e. Install the washer 3 .
f. Install the upper ring nut 2 .
g. Finger tighten the upper ring nut 2 , then
align the slots of both ring nuts.
If necessary, hold the lower ring nut and
tighten the upper ring nut until their slots are
aligned.
h. Install the lock washer 1 .
NOTE:
Make sure that the lock washer tabs a sit correctly in the ring nut slots b .
8. Install:
steering stem nut
upper bracket bolt
handlebar pinch bolt
upper bracket pinch bolt
115 Nm (11.5 mkg)
13 Nm (1.3 mkg)
13 Nm (1.3 mkg)
23 Nm (2.3 mkg)
9. Measure:
steering head tension
(with the motorcycle still on the stand)
NOTE:
Make sure that all of the cables and wires are
properly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie 1 loosely around
the end of the handlebar as shown.
c. Hook a spring gauge 2 onto the plastic locking tie.
3-49
CHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK
CHK
ADJ
d. Hold the spring gauge at a 90_ angle from
the handlebar, pull the spring gauge, and record the measurement when the handlebar
starts to turn.
Steering head tension
200 500 g
e. Repeat the above procedure on the opposite
handlebar.
f. If the steering head tension is out of specification (both handlebars should be within
specification), remove the upper bracket and
loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure the
steering head tension again as described
above.
h. Repeat the above procedure until the steering head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Looseness or binding Adjust the steering
head.
EB304141
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:
S inner tube 1
Damage/scratches Replace.
S oil seal 2
Oil leakage Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
S front fork operation
Push down hard on the handlebars several
times and check if the front fork rebounds
smoothly.
Rough movement Repair.
Refer to “FRONT FORK” in chapter 7.
3-50
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
EB304153
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
Always adjust both front fork legs evenly.
Uneven adjustment can result in poor handling and loss of stability.
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
Grooves are provided to indicate the adjustment position.
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
spring preload
a. Turn the adjusting bolt 1 in direction a or
b.
Direction a
Spring preload is
increased (suspension is
harder).
Direction b
Spring preload is
decreased (suspension is
softer).
1
3-51
HARD
2
3
4
STD
5
SOFT
6
7
8
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
rebound damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Rebound damping is
increased (suspension is
harder).
Direction b
Rebound damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 12 clicks out*
Standard: 6 clicks out*
Maximum: 1 clicks out*
* from the fully turned-in position
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
compression damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Compression damping is
increased (suspension is
harder).
Direction b
Compression damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 11 clicks out*
Standard: 6 clicks out*
Maximum: 1 clicks out*
* from the fully turned-in position
3-52
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
EB304162
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
spring preload
NOTE:
Adjust the spring preload with the special
wrench and extension bar included in the owner’s tool kit.
a. Turn the adjusting ring 1 in direction a or
b.
b. Align the desired position on the adjusting
ring with the position indicator 2 .
Direction a
Spring preload is
increased (suspension is
harder).
Direction b
Spring preload is
decreased (suspension is
softer).
Adjusting positions
Minimum: 1
Standard: 4
Maximum: 9
3-53
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
rebound damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Rebound damping is
increased (suspension is
harder).
Direction b
Rebound damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 25 clicks out*
Standard: 9 clicks out*
Maximum: 1 click out*
* from the fully turned-in position
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
compression damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Compression damping is
increased (suspension is
harder).
Direction b
Compression damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 13 clicks out*
Standard: 7 clicks out*
Maximum: 1 click out*
* from the fully turned-in position
3-54
CHECKING THE TIRES
CHK
ADJ
EB304170
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Measure:
tire pressure
Out of specification Regulate.
WARNING
The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and accessories) and the anticipated riding
speed.
Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil
and a full
fuel tank)
188 kg
Maximum
load*
187 kg
Cold tire
pressure
Front
Rear
Up to 90 kg
load*
250 kPa
250 kPa
(2.5 kgf/cm2, (2.5 kgf/cm2,
2.5 bar)
2.5 bar)
90 kg maximum load*
250 kPa
290 kPa
(2.5 kgf/cm2, (2.9 kgf/cm2,
2.5 bar)
2.9 bar)
High-speed
riding
250 kPa
250 kPa
(2.5 kgf/cm2, (2.5 kgf/cm2,
2.5 bar)
2.5 bar)
* total of cargo, rider, passenger and accessories
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
3-55
CHECKING THE TIRES
CHK
ADJ
2. Check:
tire surfaces
Damage/wear Replace the tire.
Minimum tire tread depth
1.6 mm
1 Tire tread depth
2 Side wall
3 Wear indicator
WARNING
A
B
Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure
and personal injury from sudden deflation.
When using a tube tire, be sure to install the
correct tube.
Always replace a new tube tire and a new
tube as a set.
To avoid pinching the tube, make sure that
the wheel rim band and tube are centered in
the wheel groove.
Patching a punctured tube is not recommended. If it is absolutely necessary to do so,
use great care and replace the tube as soon
as possible with a good quality replacement.
A Tire
B Wheel
Tube wheel
Tube tire only
Tubeless wheel
Tube or tubeless
tire
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this
motorcycle.
Front tire
Manufacturer
3-56
Size
Model
BRIDGESTONE
120 / 60 ZR17
(55W)
BT56FE
DUNLOP
120 / 60 ZR17
(55W)
D207FJ
CHECKING THE TIRES/CHECKING THE WHEELS
CHK
ADJ
Rear tire
Manufacturer
Size
Model
BRIDGESTONE
180/55 ZR17
(73W)
BT56RE
DUNLOP
180/55 ZR17
(73W)
D207N
WARNING
After mounting a new tire, ride conservatively for a while to become accustomed to
the “feel” of the new tire and to allow the tire
to seat itself properly in the rim. Failure to do
so could lead to an accident with possible
injury to the rider or damage to the motorcycle.
NOTE:
For tires with a direction of rotation mark 1 :
Install the tire with the mark pointing in the
direction of wheel rotation.
Align the mark 2 with the valve installation
point.
EB304180
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:
wheel
Damage/out-of-round Replace.
WARNING
Never attempt to make any repairs to the
wheel.
NOTE:
After a tire or wheel has been changed or replaced, always balance the wheel.
3-57
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVERS AND PEDALS/
LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION
CHK
ADJ
EB304200
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the
cable sheaths and cables.
WARNING
Damaged cable sheaths may cause the
cable to corrode and interfere with its movement. Replace damaged cable sheaths and
cables as soon as possible.
1. Check:
cable sheath
Damage Replace.
2. Check:
cable operation
Rough movement Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suitable lubing device.
EB304210
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium soap base grease
EB304220
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium soap base grease
EB304240
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Lithium soap base grease
3-58
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
EB305020
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling or
working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or handling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
Skin – Wash with water
Eyes – Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
Drink large quantities of water or milk followed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical
attention.
CAUTION:
This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery
performance will deteriorate.
Charging time, charging amperage and
charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as
explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging the battery.
3-59
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:
S rider seat
Refer to “SEATS”.
2. Disconnect:
S battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative lead 2 , then
the positive lead 1 .
3. Remove:
S battery
4. Measure:
S battery charge
a. Connect a digital voltmeter to the battery terminals.
Open-circuit voltage (V)
Tester positive probe battery positive
terminal
Tester negative probe battery negative terminal
13.0
NOTE:
S The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive terminal is
disconnected).
S No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
Relationship between the open-circuit voltage
and the charging time at 20_C
12.5
12.0
11.5
5 6.5
10
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20 30%
3-60
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
5. Charge:
S battery
(refer to the appropriate charging method illustration)
Charging
Open-circuit voltage (V)
Ambient temperature 20_C
WARNING
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage.
CAUTION:
S Never remove the MF battery sealing caps.
S Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause battery overheating and battery plate damage.
S If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
S When charging a battery, be sure to remove it from the motorcycle. (If charging
has to be done with the battery mounted on
the motorcycle, disconnect the negative
lead from the battery terminal.)
S To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
S Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
S Make sure that the battery charger lead
clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip
spring may cause sparks.
S If the battery becomes hot to the touch at
any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode!
S As shown in the following illustration, the
open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has
been completed. Therefore, wait 30 minutes after charging is completed before
measuring the open-circuit voltage.
Open-circuit voltage (V)
Ambient
temperature
20_C
Charging condition of the battery (%)
3-61
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Charging method using a variable-voltage charger
Charger
Ammeter
Measure the open-circuit
voltage prior to charging.
Connect a charger and ammeter to the battery and
start charging.
YES
Is the amperage higher
than the standard charging
amperage written on the
battery?
NOTE:
Leave the battery unused for more than
30 minutes before measuring its opencircuit voltage.
NOTE:
Set the charging voltage to 16 17 V.
(If the charging voltage is lower, charging will be insufficient, if it is higher, the
battery will be over-charged.)
NO
Adjust the charging voltage to
20 25 V.
Adjust the voltage to obtain the
standard charging amperage.
YES
Monitor the amperage for 3 5 minutes. Is the standard
charging amperage exceeded?
NO
Set the timer to the charging
time determined by the opencircuit voltage.
Refer to “CHECKING AND
CHARGING THE BATTERY”.
If the amperage does not
exceed the standard charging amperage after 5 minutes, replace the battery.
If the required charging time exceeds 5 hours, it is advisable to check
the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.
12.8 V Charging is complete.
12.0 12.7 V Recharging is required.
Under 12.0 V Replace the battery.
3-62
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Charging method using a constant-voltage charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for more than
30 minutes before measuring its opencircuit voltage.
Connect a charger and ammeter to the battery and
start charging.
YES
Is the amperage higher
than the standard charging
amperage written on the
battery?
Charge the battery until the charging
voltage reaches 15 V.
NO
This type of battery charger cannot
charge an MF battery. A variablevoltage charger is recommended.
NOTE:
Set the charging time to a maximum of
20 hours.
Charger
Leave the battery unused for more
than 30 minutes before measuring its
open-circuit voltage.
12.8 V Charging is complete.
12.0 12.7 V Recharging is required.
Under 12.0 V Replace the battery.
Ammeter
Voltmeter
CAUTION:
Constant amperage chargers are not
suitable for charging MF batteries.
3-63
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
CHK
ADJ
6. Install:
battery
7. Connect:
battery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1 , then the
negative lead 2 .
8. Check:
battery terminals
Dirt Clean with a wire brush.
Loose connection Connect properly.
9. Lubricate:
battery terminals
Recommended lubricant
Dielectric grease
10. Install:
rider seat
Refer to “SEATS”.
EB305040
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
CAUTION:
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:
rider seat
Refer to “SEATS”.
2. Check:
continuity
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω
1”.
Pocket tester
90890-03112
b. If the pocket tester indicates “∞”, replace the
fuse.
3-64
CHECKING THE FUSES
CHK
ADJ
3. Replace:
blown fuse
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage.
c. Set the main switch to “ON” and verify if the
electrical circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Item
Amperage
Q’ty
Main fuse
30 A
1
Headlight
fuse
20 A
1
Signaling
system fuse
20 A
1
Ignition
fuse
15 A
1
Radiator
fan motor
fuse
7.5 A
1
Backup fuse
(odometer)
7.5 A
1
WARNING
Never use a fuse with an amperage other
than that specified. Improvising or using a
fuse with the wrong amperage rating may
cause extensive damage to the electrical
system, cause the lighting and ignition systems to malfunction and could possibly
cause a fire.
4. Install:
rider seat
Refer to “SEATS”.
3-65
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
EB305051
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Disconnect:
headlight coupler 1
headlight bulb holder cover 2
2. Detach:
headlight bulb holder 1
3. Remove:
headlight bulb 2
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
4. Install:
headlight bulb New
Secure the new headlight bulb with the headlight bulb holder.
CAUTION:
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
5. Attach:
headlight bulb holder
6. Install:
headlight bulb holder cover
7. Connect:
headlight coupler
3-66
ADJUSTING THE HEADLIGHT BEAMS
CHK
ADJ
EB305061
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
1. Adjust:
headlight beam (vertically)
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Headlight beams is raised.
Direction b
Headlight beams is lowered.
2. Adjust:
headlight beam (horizontally)
a. Turn the adjusting knob 1 in direction a or
b.
Left headlight
Direction a
Headlight beam moves
to the right.
Direction b
Headlight beams moves
to the left.
Right headlight
3-67
Direction a
Headlight beam moves
to the left.
Direction b
Headlight beam moves
to the right.
CHK
ADJ
ENG
4
ENG
CHAPTER 4.
OVERHAULING THE ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAD AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-2
4-3
4-5
4-6
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMCHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFT SPROCKETS
AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . .
INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7
4-7
4-8
4-10
4-11
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17
4-18
4-18
4-19
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . .
CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20
4-22
4-23
4-25
4-27
4-28
4-28
4-12
4-13
4-14
PICKUP COIL AND PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . . 4-31
REMOVING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 4-33
INSTALLING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 4-33
STARTER CLUTCH AND GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-35
4-37
4-38
4-38
4-39
4-39
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-40
4-42
4-42
4-42
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
ENG
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PULL LEVER SHAFT AND PULL ROD . . . . . . . . .
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-46
4-48
4-48
4-49
4-49
4-49
4-50
4-50
4-50
4-51
OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE . . . . . . . . . . .
CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-53
4-56
4-56
4-57
4-57
4-57
4-57
4-57
4-58
4-58
4-58
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL BAFFLE PLATES AND OIL FILTER BOLT . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . .
CHECKING THE SPROCKETS AND CHAINS . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-59
4-61
4-62
4-63
4-63
4-63
4-64
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . . .
CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BIG END BEARINGS . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE PISTONS AND CONNECTING RODS . . . . . . . .
4-66
4-68
4-69
4-70
4-71
4-72
4-74
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT JOURNAL BEARINGS . . . . . . . . .
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-78
4-79
4-79
4-79
4-82
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-83
4-89
4-89
4-90
4-90
4-91
ENGINE
ENG
EAS00190
OVERHAULING THE ENGINE
ENGINE
DRIVE SPROCKET
10 Nm (1.0 mkg)
70 Nm (7.0 mkg)
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CHANGING THE COOLANT”
Removing the drive sprocket
Reserve tank
Locknut
Shift rod
Shift arm
Drive sprocket cover
Nut
Lock washer
Drive sprocket
2
1
1
1
1
1
1
For installation reverse the remove
procedure.
4-1
ENGINE
ENG
EXHAUST ASSEMBLY
38 Nm (3.8 mkg)
20 Nm (2.0 mkg)
20 Nm (2.0 mkg)
20 Nm (2.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “COWLINGS” in chapter 3
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “RADIATOR” in chapter 5.
Removing the exhaust assembly
Bottom cowling and side cowlings
Coolant
1
2
3
Remarks
Radiator assembly
Muffler
Exhaust pipe assembly
Exhaust pipe gasket
1
1
4
For installation reverse the removal
procedure.
4-2
ENGINE
ENG
LEADS AND HOSES
Order
Job/Part
Q’ty
Remarks
Disconnect the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE AND
IGNITION COILS” in chapter 3.
Refer to “CARBURETORS” in chapter 6.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “OIL COOLER” in chapter 5.
Disconnecting the leads and hoses
Fuel tank
Air filter case
Carburetor assembly and joints
Engine oil and oil filter cartridge
Oil cooler
4-3
ENGINE
Order
1
2
Job/Part
Q’ty
1
1
Battery negative lead
Battery positive lead
ENG
Remarks
CAUTION:
First, disconect the negative lead, then
the positive lead.
3
4
5
6
7
8
1
1
1
1
1
1
Startor coil assembly coupler
Pickup coil coupler
Engine earth
Clutch wire and holder
Crankcase breather hose
Separator
For connecting reverse the discomecting
procedure.
4-4
ENGINE
ENG
ENGINE
24 Nm (2.4 mkg)
55 Nm (5.5 mkg)
45 Nm (4.5 mkg)
38 Nm (3.8 mkg)
13 Nm (1.3 mkg)
55 Nm (5.5 mkg)
24 Nm (2.4 mkg)
7 Nm (0.7 mkg)
Order
Job/Part
Q’ty
Remove The Parts In The Order Listed.
NOTE:
Place a suitable stand under the frame and
engine.
Removing the engine
1
2
3
4
5
6
7
Remarks
4
2
2
2
2
2
2
Pinch bolts
Button head bolts
Collars
Front mounting bolts
Collars
Rear mounting bolts
Engine mounting adjust bolts
Refer to “INSTALLING THE ENGINE”.
NOTE:
Use the point shaft wrench to loosen the
engine mounting adjust bolt.
For Installation, Reverse The Removal
Procedure.
4-5
ENGINE
ENG
EAS00192
INSTALLING THE ENGINE
1. Install:
engine mounting adjust bolts 1
rear mounting bolts 2
self-locking nuts 3
collars 4
front mounting bolts 5
collars 6
button head bolts 7
pinch bolts 8
NOTE:
Lubricate the rear mounting bolt threads with
lithium soap base grease.
Do not fully tighten the nuts and bolts.
2. Tighten:
self-locking nut
front mounting bolts
button head bolt
pinch bolt
M8
M6
engine adjusting bolts
47 Nm (4.7mkg)
55 Nm (5.5 mkg)
39 Nm (3.9 mkg)
24 Nm (2.4 mkg)
13 Nm (1.3 mkg)
NOTE:
Use the pivot shaft wrench 1 to tighten the engine mounting adjust bolt to finger tightness.
Pivot shaft wrench
90890-01471
3. Install:
drive sprocket
4. Install:
drive sprocket cover
70Nm (7.0 mkg)
10 Nm (1.0 mkg)
NOTE:
Refer to “CABLE ROUTING” in chapter 2.
5. Install:
shift arm 1
10 Nm (1.0 mkg)
NOTE:
Align the punch mark a in the shift shaft with
the slot in the shift arm.
4-6
CAMSHAFTS
ENG
EAS00194
CAMSHAFTS
CYLINDER HEAD COVER
13 Nm (1.3 mkg)
10 Nm (1.0 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CARBURETORS” in chapter 6.
Refer to “RADIATOR” in chapter 5.
Removing the cylinder head cover
Carburetor assembly
Radiator assembly
Spark plugs
Cylinder head cover
Cylinder head cover gasket
Timing chain guide (top side)
4
1
1
1
For installation reverse the removal
procedure.
4-7
CAMSHAFTS
ENG
EAS00196
CAMSHAFTS
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
12 Nm (1.2 mkg)
24 Nm (2.4 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “PICKUP COIL AND PICK UP
COIL COVER”.
Removing the camshafts
Pickup coil rotor cover
1
2
3
4
5
Timing chain tensioner
Timing chain tensioner gasket
Camshaft cap
Camshaft cap gasket
Dowel pin
1
1
1
4
2
6
7
8
Intake camshaft
Exahust camshaft
Timing chain guide (exhaust side)
1
1
1
4-8
Refer to “REMOVING/INSTALLING
THE CAMSHAFTS”.
NOTE:
During removal, the dowel pins may still
be connected to the camshaft cap.
Refer to “REMOVING/INSTALLING
THE CAMSHAFT”.
CAMSHAFTS
10 Nm (1.0 mkg)
ENG
10 Nm (1.0 mkg)
12 Nm (1.2 mkg)
24 Nm (2.4 mkg)
Order
9
10
11
12
Job/Part
Q’ty
Intake camshaft sproket
Exhaust camshaft sproket
Pin
Timing chain guide (intake side)
1
1
1
1
Remarks
Refer to “INSTALLING THE
CAMSHAFTS”.
For installation reverse the removal
procedure.
4-9
CAMSHAFTS
ENG
EAS00198
REMOVING THE CAMSHAFTS
1. Align:
TDC mark on the pickup coil rotor (with the
crankcase mating surface)
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the mark a on the pickup
coil rotor with the crankcase mating surface
b.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
2. Remove:
timing chain tensioner
3. Remove:
camshaft cap
dowel pins
CAUTION:
To prevent damage to the cylinder head,
camshafts or camshaft cap, loosen the camshaft cap bolts in stages and in a crisscross
pattern, working from the outside in.
4. Remove:
intake camshaft 1
exhaust camshaft 2
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 3 .
5. Remove:
timing chain guide (exhaust side)
4-10
CAMSHAFTS
ENG
EAS00204
CHECKING THE CAMSHAFTS
1. Check:
camshaft lobes
Blue discoloration/pitting/scratches Replace the camshaft.
2. Measure:
camshaft lobe dimensions a and b
Out of specification Replace the camshaft.
Camshaft lobe dimensions limit
Intake camshaft
a 33.0 mm
b 25.09 mm
Exhaust camshaft
a 32.50 mm
b 25.02 mm
3. Measure:
camshaft runout
Out of specification Replace.
Max. camshaft runout
0.06 mm
4. Measure:
camshaft-journal-to-camshaft-cap
clearance
Out of specification Measure the camshaft journal diameter.
Camshaft-journal-to-camshaftcap
clearance
0.020 0.054 mm
<Limit>: 0.08 mm
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position a strip of Plastigauge 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.
4-11
CAMSHAFTS
ENG
NOTE:
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.
Do not turn the camshaft when measuring the
camshaft-journal-to-camshaft-cap clearance
with the Plastigauge.
Camshaft cap bolt
10 Nm (1.0 mkg)
d. Remove the camshaft caps and then measure the width of the Plastigauge 1 .
5. Measure:
camshaft journal diameter a
Out of specification Replace the camshaft.
Within specification Replace the cylinder
head and the camshaft caps as a set.
Camshaft journal diameter
22.967 22.980 mm
EAS00208
CHECKING THE CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
4-12
CAMSHAFTS
ENG
1. Check:
camshaft sprocket
More than 1/4 tooth wear a Replace the
camshaft sprockets and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
2. Check:
timing chain guide (exhaust side) 1
timing chain guide (intake side) 2
timing chain guide (top side) 3
Damage/wear Replace the defective
part(-s).
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
timing chain tensioner
Cracks/damage/rough movement Replace.
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
NOTE:
While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver 1 until
it stops.
b. Remove the screwdriver and slowly release
the timing chain tensioner rod.
c. Make sure that the timing chain tensioner rod
comes out of the timing chain tensioner
housing smoothly. If there is rough movement, replace the timing chain tensioner.
4-13
CAMSHAFTS
ENG
INSTALLING THE CAMSHAFTS
1. Install:
timing chain guide (intake side)
timing chain guide (exhaust side)
2. Install:
intake camshaft sprocket
24 Nm (2.4 mkg)
exhaust camshaft sprocket
24 Nm (2.4 mkg)
NOTE:
Cam sprocket timing mark is outside and align
the cam sprocket hole to camshaft hole.
3. Install:
exhaust camshaft 3
intake camshaft 2
camshaft cap gasket
camshaft cap
NOTE:
The brim 1 of intake camshaft is not processed.
The groove is processed around the brim 1 of
exhaust cameshaft as illustration.
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the a mark on the pickup
coil rotor with the crankcase mating surface
b.
c. Install the timing chain onto both camshaft
sprockets and then install the camshaft
sprockets onto the camshafts.
CAUTION:
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
d. Install the exhaust and intake camshaft cap.
Camshaft cap bolt
10 Nm (1.0 mkg)
4-14
CAMSHAFTS
ENG
NOTE:
Make sure that the camshaft sprocket timing
marks c are aligned with the cylinder head
edge d
Out of alignment Reinstall.
e. Remove the wire from the timing chain.
4. Install:
timing chain tensioner
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
b. While pressing the timing chain tensioner
rod, wind it clockwise with a thin screwdriver
1 until if stops.
C. With the screwdriver still inserted into the
timing chain tensioner, install the timing
chain tensioner 2 , gasket, and float chamber air vent hose holder 3 onto the cylinder
block. Then, tighten the timing chain tensioner bolts 4 to the specified torque.
WARNING
Always use a new gasket.
NOTE:
The “UP” mark on the timing chain tensioner
should face up.
Timing chain tensioner bolt
12 Nm (1.2 mkg)
d. Remove the screwdriver, make sure that the
timing chain tensioner rod releases, and
tighten the cap bolt to the specified torque.
Cap bolt
10 Nm (1.0 mkg)
5. Turn:
crankshaft (several turns counterclockwise)
4-15
CAMSHAFTS
ENG
6. Check:
TDC mark a
Make sure that the TDC mark is aligned with
the crankcase mating surface b .
camshaft sprocket timing mark c
Make sure that the camshaft sprocket timing
mark is aligned with the cylinder head edge
d
Out of alignment Adjust.
Refer to the installation steps above.
7. Measure:
valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3.
8. Install:
cylinder head cover gasket
cylinder head cover
NOTE:
Apply bond TB1541 onto the mating surfaces
of the cylinder head cover and cylinder head
cover gasket.
Apply bond 1215B onto the mating surfaces of
the cylinder head cover gasket and cylinder
head.
Tighten the cylinder head cover bolts in stages
and in a crisscross pattern.
4-16
CYLINDER HEAD
ENG
EAS00220
CYLINDER HEAD
51 Nm (5.1 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
1
Removing the cylinder head
Intake and exhaust camshafts
Water hose
Temp senser lead
Front mounting bolt
Cylinder head
1
2
3
Cylinder head gasket
Dowel pin
1
2
Remarks
Remove the parts in the order listed.
Refer to “CAMSHAFTS”.
Disconnect
Disconnect
Refer to “ENGINE”.
Refer to “REMOVING/INSTALLING THE
CYLINDER HEAD”.
For installation reverse the removal
procedure.
4-17
CYLINDER HEAD
ENG
EAS00223
REMOVING THE CYLINDER HEAD
1. Remove:
cylinder head bolts
cylinder head
NOTE:
Loosen each bolt and nut 1/2 of a turn at a time,
in stages and in a crisscross pattern. After all of
the bolts and nuts are fully loosened, remove
them.
EAS00229
CHECKING THE CYLINDER HEAD
1. Eliminate:
combustion chamber carbon deposits (with
a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
spark plug bore threads
valve seats
2. Check:
cylinder head
Damage/scratches Replace.
cylinder head water jacket
Mineral deposits/rust Eliminate.
3. Measure:
cylinder head warpage
Out of specification Resurface the cylinder head.
Max. cylinder head warpage
0.05 mm
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limited in exceeded, resurface the cylinder head as follows.
4-18
CYLINDER HEAD
ENG
d. Place a 400 600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
EAS00223
INSTALLING THE CYLINDER HEAD
1. Install:
cylinder head gasket
cylinder head
cylinder headbolt
51 Nm (5.1 mkg)
(M10)
(M6)
10 Nm (1.0 mkg)
NOTE:
Lubricate the cylinder head nuts with engine
oil.
Tighten the cylinder head nuts and bolts in two
stages and in a crisscross pattern.
4-19
VALVES AND VALVE SPRINGS
ENG
EAS00236
VALVES AND VALVE SPRINGS
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the valves and valve
springs
Cylinder head
Intake valve lifter
Intake valve pad
Intake valve cotter
Intake valve upper spring seat
Intake valve spring outer
Intake valve spring inner
Intake valve oil seal
Intake valve lower spring seat
Intake valve
Intake valve guide
Refer to “CYLINDER HEAD”.
8
8
16
8
8
8
8
8
8
8
4-20
Refer to “REMOVING/INSTALLING
THE VALVES”.
VALVES AND VALVE SPRINGS
Order
11
12
13
14
15
16
17
18
19
Job/Part
Q’ty
8
8
16
8
8
8
8
8
8
Exhaust valve lifter
Exhaust valve pad
Exhaust valve cotter
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve oil seal
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide
ENG
Remarks
Refer to “REMOVING/INSTALLING THE
VALVES”.
For installation, reverse the removal
procedure.
4-21
VALVES AND VALVE SPRINGS
ENG
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
NOTE:
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure that the valves properly seal.
1. Remove:
valve lifter 1
valve pad 2
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
valve
(for leakage)
Leakage at the valve seat Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat
1.
4-22
VALVES AND VALVE SPRINGS
ENG
3. Remove:
valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .
Valve spring compressor
90890-04019
Attachment
90890-04114
4. Remove:
upper spring seat 1
valve spring outer 2
valve spring inner (intake only) 3
valve 4
oil seal 5
lower spring seat 6
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
EAS00239
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification Replace the valve
guide.
Valve-stem-to-valve-guide clearance
Intake
0.010 0.037 mm
<Limit> : 0.08 mm
Exhaust
0.025 0.052 mm
<Limit>: 0.1 mm
4-23
VALVES AND VALVE SPRINGS
ENG
2. Replace:
S valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100_C (212_C) in an oven.
a. Remove the valve guide with a valve guide
remover 1 .
b. Install the new valve guide with the valve
guide installer 2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with a valve guide reamer 3 to
obtain the proper valve-stem-to-valve-guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat .
Valve guide remover
Intake (4.0 mm),
Exhaust (4.0 mm)
90890-04111
Valve guide installer
Intake (4.0 mm),
Exhaust (4.0 mm)
90890-04112
Valve guide reamer
Intake and Exhaust
90890-04113
3. Eliminate:
S carbon deposits
(from the valve face and valve seat)
4. Check:
S valve face
Pitting/wear Grind the valve face.
S valve stem end
Mushroom shape or diameter larger than the
body of the valve stem Replace the valve.
4-24
VALVES AND VALVE SPRINGS
ENG
5. Measure:
valve margin thickness a
Out of specification Replace the valve.
Valve margin thickness
0.6 mm 0.8 mm
<LIMIT>: 0.5mm
6. Measure:
valve stem runout
Out of specification Replace the valve.
NOTE:
When installing a new valve, always replace
the valve guide.
If the valve is removed or replaced, always replace the oil seal.
Valve stem runout
0.04 mm
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
carbon deposits
(from the valve face and valve seat)
2. Check:
valve seat
Pitting/wear Replace the cylinder head.
3. Measure:
valve seat width a
Out of specification Replace the cylinder
head.
Valve seat width
Intake: 0.9 1.1 mm
<Limit>: 1.6 mm
4-25
VALVES AND VALVE SPRINGS
ENG
a. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been removed.
4. Lap:
valve face
valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
a. Apply a coarse lapping compound a to the
valve face.
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth between your hand.
4-26
VALVES AND VALVE SPRINGS
ENG
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width c again. If the
valve seat width is out of specification, reface
and lap the valve seat.
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
valve spring free length a
Out of specification Replace the valve
spring.
Valve spring free length
Intake valve spring (inner)
37.0 mm
<Limit>: 35mm
Intake valve spring (outer)
38.4 mm
<Limit>: 36.5mm
Exhaust valve spring
41.7 mm
<Limit>: 39.5mm
4-27
VALVES AND VALVE SPRINGS
ENG
2. Measure:
compressed spring force a
Out of specification Replace the valve
spring.
b Installed length
Compressed spring force
(installed)
Intake valve spring inner
7.0 8.0 kg at 30.0 mm
Intake valve spring outer
11.6 13.4 kg at 32.5 mm
Exhaust valve spring
16.3 18.7 kg at 36.1 mm
3. Measure:
valve spring tilt a
Out of specification Replace the valve
spring.
Max. Spring tilt
Intake valve spring inner
1.6 mm
Intake valve spring outer
1.7 mm
Exhaust valve spring
1.8 mm
EAS00242
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:
valve lifter
Damage/scratches Replace the valve lifters and cylinder head.
EAS00247
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
valve stem end
(with an oil stone)
2. Lubricate:
valve stem 1
oil seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
4-28
VALVES AND VALVE SPRINGS
ENG
3. Install:
lower spring seat 6
oil seal 5 New
valve 4
valve spring inner (intake only) 3
valve spring outer 2
upper spring seat 1
(into the cylinder head)
NOTE:
Make sure that each valve is installed in its
original place. Refer to the following embossed marks.
Install the valve spring with the larger pitch a
facing up.
b Smaller pitch
4. Install:
valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .
Valve spring compressor
90890-04019
Attachment
90890-04114
5. To secure the valve cotters 1 onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
4-29
VALVES AND VALVE SPRINGS
ENG
6. Lubricate:
valve pad
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
7. Install:
valve pad
valve lifter
NOTE:
The valve lifter must move smoothly when rotated with a finger.
Each valve lifter and valve pad must be reinstalled in its original position.
4-30
PICKUP COIL AND PICKUP COIL ROTOR
ENG
PICKUP COIL AND PICKUP COIL ROTOR
10 Nm (1.0 mkg)
15 Nm (1.5 mkg)
35 Nm (3.5 mkg)
12 Nm (1.2 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the pickup coil and
pickup coil rotor
Riders seat and fuel tank
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “COWLINGS” in chapter 3.
Bottom cowling and right side
cowling
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Generator cover
4-31
PICKUP COIL AND PICKUP COIL ROTOR
ENG
10 Nm (1.0 mkg)
15 Nm (1.5 mkg)
35 Nm (3.5 mkg)
12 Nm (1.2 mkg)
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
1
1
1
1
1
2
1
1
Clutch cable
Clutch cable holder
Pickup coil coupler
Pickup coil cover
Pickup coil cover gasket
Dowel pin
Pickup coil
Pickup rotor
Remarks
Disconnect
Refer to “REMOVING/INSTALLING
THE PICKUP COIL ROTOR”.
For installation reverse the removal
procedure.
4-32
PICKUP COIL AND PICKUP ROTOR
ENG
REMOVING THE PICKUP COIL ROTOR
1. Remove:
clutch cable holder 1
pickup coil cover 2
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
2. Remove:
pickup coil rotor bolt 1
plain washer 2
pickup coil rotor 3
NOTE:
While holding the generator rotor 4 with the rotor holding tool 5 , loosen the pickup coil rotor
bolt.
Sheave holder
90890-01701
INSTALLING THE PICKUP COIL ROTOR
1. Install:
pickup coil rotor 1
plain washer
pickup coil rotor bolt
NOTE:
When installing the pickup coil rotor, align the
pin 2 in the crankshaft sprocket with the
groove a in the pickup coil rotor.
4-33
PICKUP COIL AND PICKUP ROTOR
ENG
2. Tighten:
pickup coil rotor bolt 1
35 Nm (3.5 mkg)
NOTE:
While holding the generator rotor 2 with the
sheave holder 3 , tighten the pickup coil rotor
bolt.
Sheave holder
90890-01701
3. Apply:
sealant
(onto the pickup coil lead grommet)
Yamaha bond No.1215
90890-85505
4. Install:
pickup coil cover
clutch cable holder
NOTE:
When installing the pickup coil cover, align the
timing chain guide (intake side) pin 1 of the
with the hole 2 in the pickup coil cover.
Tighten the pickup coil cover bolts in stages
and in a crisscross pattern.
4-34
STARTER CLUTCH AND GENERATOR
ENG
EAS00341
STARTER CLUTCH AND GENERATOR
65 Nm (6.5 mkg)
10 Nm (1.0 mkg)
12 Nm (1.2 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the starter clutch and generator
Riders seat and fuel tank
Buttom and left side cowlings
Engine oil
Coolant treserver
1
2
Stator coil assembly coupler
Generator cover
1
1
3
4
5
6
Generator rotor cover gasket
Dowel pin
Stator coil assembly lead holder
Stator coil assembly
1
2
1
1
4-35
Remarks
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Refer to “REMOVING/INSTALLING
THE GENERATOR”.
STARTER CLUTCH AND GENERATOR
ENG
65 Nm (6.5 mkg)
10 Nm (1.0 mkg)
12 Nm (1.2 mkg)
Order
7
8
9
10
11
12
13
Job/Part
Q’ty
1
1
1
1
1
1
1
Generator rotor bolt
Plain washer
Generator rotor
Starter one-way assy
Idler gear shaft
Idler hear
Starter clutch gear
Remarks
Refer to “REMOVING/INSTALLING
THE GENERATOR”.
For installation reverse the removal
proceduer.
4-36
STARTER CLUTCH AND GENERATOR
ENG
EAS00346
REMOVING THE GENERATOR
1. Remove:
generator rotor cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
2. Remove:
generator rotor bolt 1
Plain washer
NOTE:
While holding the generator rotor 2 with the
sheave holder 3 , loosen the generator rotor
bolt.
Do not allow the sheave holder to touch the projection on the generator rotor.
Sheave holder
90890-01701
3. Remove:
generator rotor 1
(with the flywheel puller 2 and adapter 3 )
Flywheel puller
90890-01362
Flywheel puller attachment
90890-04089
4-37
STARTER CLUTCH AND GENERATOR
ENG
EAS00345
REMOVING THE STARTER CLUTCH
1. Remove:
Generator
Starter one-way assy 1
Idler gear shaft 2
Idler gear 3
Starter clutch gear 4
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
Starter one-way assy
Damage/wear Replace.
2. Check:
Idler gear
Idler gear shaft
starter clutch gear
Pitting/Burrs/chips/roughness/wear Replace the defective parts.
3. Check:
Starter clutch operation
a. Install the starter clutch gear 1 onto the
starter clutch 2 and hold the starter clutch.
b. When turning the starter clutch drive gear
clockwise A , the starter clutch and the starter clutch gear should engage.
If the starter clutch gear and starter clutch do
not engage, the starter clutch is faulty and
must be replaced.
c. When turning the starter clutch drive gear
counterclockwise B , it should turn freely. If
the starter clutch drive gear does not turn
freely, the starter clutch is faulty and must be
replaced.
4-38
STARTER CLUTCH AND GENERATOR
ENG
EAS00355
INSTALLING THE STARTER CLUTCH
1. Install:
starter clutch gear 1
idler gear 2
idler gear shaft 3
startor one-way assy 4
EAS00354
INSTALLING THE GENERATOR
1. Install:
generator rotor 1
washer 2
generator rotor bolt 3
NOTE:
Clean the tapered portion of the crankshaft and
the generator rotor hub with lacquer tinner.
2. Tighten:
generator rotor bolt 3
65 Nm (6.5 mkg)
NOTE:
While holding the generator rotor 2 with the
sheave holder 3 , tighten the generator rotor
bolt.
Do not allow the sheave holder to touch the projection on the generator rotor.
Sheave holder
90890-01701
3. Apply:
sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No.1215
90890-85505
4. Install:
stator coil
5. Install:
generator rotor cover
NOTE:
Tighten the generator rotor cover bolts in stages
and in a crisscross pattern.
4-39
SHIFT SHAFT
ENG
EAS00327
SHIFT SHAFT
22 Nm (2.2 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Drain.
Refer to “CHNGING THE COOLANT” in
chapter 3.
Refer to “ENGINE”.
Removing the shift shaft
Coolant reserver
1
2
3
4
5
Remarks
Drive sprocket cover, sift rod and sift
arm.
Shift shaft cover
Shift shaft cover gasket
Dowel pin
Oil seal
Sift shaft
1
1
2
1
1
4-40
Refer to “INSTALLING THE SHIFT
SHAFT”.
SHIFT SHAFT
ENG
22 Nm (2.2 mkg)
Order
6
7
8
9
10
11
12
13
14
Job/Part
Q’ty
1
1
1
1
1
1
1
1
1
Shift shaft spring
Collar
Stopper lever spring
Circrip
Washer
Stopper lever
Collar
Washer
Shift shaft spring stopper
Remarks
Refer to “INSTALLING THE SHIFT
SHAFT”.
For installation reverse the removal
procedure.
4-41
SHIFT SHAFT
ENG
EAS00329
CHECKING THE SHIFT SHAFT
1. Check:
shift shaft 1
Bends/damage/wear Replace.
shift shaft spring 2
Damage/wear Replace.
EAS00330
CHECKING THE STOPPER LEVER
1. Check:
stopper lever 1
Bends/damage Replace.
Roller turns roughly Replace the stopper
lever.
EAS00334
INSTALLING THE SHIFT SHAFT
1. Install:
shift shaft spring stopper 1
22 Nm (2.2 mkg)
stopper lever spring 2
washer
stopper lever 3
NOTE:
Apply LOCTITE to the threads of the shift
shaft spring stopper.
Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss.
Mesh the stopper lever with the shift drum segment assembly.
2. Install:
shift shaft 1
collor
NOTE:
Lubricate the oil seal lips with lithium soap
base grease.
Install the end of the shift shaft spring onto the
shift shaft spring stopper 2
4-42
CLUTCH
ENG
EB405000
CLUTCH
CLUTCH COVER
12 Nm (1.2 mkg)
12 Nm (1.2 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Removing the clutch cover
Bottom cowing and right side cowling
Engine oil
Coolant
1
2
Remarks
Therm bypass hose
Clutch cable
1
1
4-43
CLUTCH
ENG
12 Nm (1.2 mkg)
12 Nm (1.2 mkg)
Order
Job/Part
Q’ty
3
Clutch cover
1
4
5
Clutch cover gasket
Dowel pin
1
2
Remarks
Refer to “REMOVING/INSTALLING
THE CLUTCH”.
For installation reverse the removal
procedure.
4-44
CLUTCH
Order
1
2
3
4
5
6
Job/Part
Q’ty
ENG
Remarks
Disassemble the parts in the order listed.
Disassembling the clutch cover
assembly
Circlip
Plain washer
Pull lever
Pull lever spring
Oil seal
Bearing
2
2
1
1
1
2
Refer to “INSTALLING THE CLUTCH”.
For assembly, reverse the disassembly
procedure.
4-45
CLUTCH
ENG
CLUTCH
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the clutch
Compression spling
Pressure plate
Pull rod
Bearing
Friction plate
Clutch plate
Clutch plate
Clutch boss nut
Look washer
Clutch boss
6
1
1
1
8
7
1
1
1
1
4-46
Refer to “INSTALLING THE CLUTCH”.
Refer to“REMOVING/INSTALLING
THE CLUTCH”.
CLUTCH
ENG
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
Order
11
Job/Part
Q’ty
Thrust plate
Remarks
1
For installation, reverse the removal
procedure.
4-47
CLUTCH
ENG
EAS00277
REMOVING THE CLUTCH
1. Remove:
clutch cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
Pressure plate
Fricttion and clutch plates
2. Straighten the lock washer tab.
3. Loosen:
clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the clutch
holding tool 3 , loosen the clutch boss nut.
Clutch holding tool
90890-04086
4. Remove:
clutch boss nut 1
lock washer 2
clutch boss 3
thrust plate 4
EAS00280
CHECKING THE FRICTION PLATES
The following procedure applies to all of the friction plates.
1. Check:
friction plate
Damage/wear Replace the friction plates
as a set.
2. Measure:
friction plate thickness
Out of specification Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate thickness
2.9 3.1 mm
<Limit>: 2.8 mm
4-48
CLUTCH
ENG
EAS00281
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
clutch plate
Damage Replace the clutch plates as a
set.
2. Measure:
clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification Replace the clutch
plates as a set.
Max. clutch plate warpage
0.1 mm
EAS00282
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
clutch spring
Damage Replace the clutch springs as a
set.
2. Measure:
clutch spring free length a
Out of specification Replace the clutch
springs as a set.
Clutch spring free length
Clutch spring free length
55 mm <Limit>: 54 mm
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:
clutch housing dogs
Damage/pitting/wear Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause erratic clutch operation.
2. Check:
bearing
Damage/wear Replace the clutch housing.
4-49
CLUTCH
ENG
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:
clutch boss splines
Damage/pitting/wear Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause erratic clutch operation.
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:
pressure plate 1
Cracks/damage Replace.
bearing 2
Damage/wear Replace.
EAS00287
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:
pull lever shaft pinion gear teeth a
pull rod teeth b
Damage/wear Replace the pull rod and
pull lever shaft as a set.
2. Check:
pull rod bearing
Damage/wear Replace.
4-50
CLUTCH
ENG
EAS00296
INSTALLING THE CLUTCH
1. Install:
thrust plate 1
clutch boss 2
2. Install:
lock washer 3 New
clutch boss nut 4
70 Nm (7.0 mkg)
NOTE:
While holding the clutch boss 2 with the clutch
holding tool 5 , tighten the clutch boss nut.
Clutch holding tool
90890-04086
3. Bend the lock washer tab along a flat side of
the nut.
4. Lubricate:
friction plates
clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Install:
friction plates
clutch plates
NOTE:
First, install a friction plate and then alternate
between a clutch plate and a friction plate.
6. Install:
washer
bearing 1
pull rod 2
NOTE:
Install the pull rod so that the teeth a face towards the rear of the motorcycle. Then, install
the clutch cover.
Tighten the clutch cover bolts in stages and in a
crisscross pattern.
Apply oil onto the bearing.
Apply molybdenum disulfide grease onto the
pull rod.
4-51
CLUTCH
7. Install:
pressure plate
clutch springs
clutch spring bolts
ENG
8 Nm (0.8 mkg)
NOTE:
Tighten the clutch spring bolts in stages and in a
criss cross pattern.
8. Install:
clutch cover
12 Nm (1.2 mkg)
NOTE:
When installing the clutch cover, push the pull
lever and check that the punch mark a on the
pull lever aligns with the mark b on the clutch
cover. Make sure that the pull rod teeth and
pull lever shaft pinion gear are engaged.
Tighten the clutch cover bolts in stages and in
a crisscross pattern.
4-52
OIL PAN AND OIL PUMP
ENG
EAS00356
OIL PAN AND OIL PUMP
10 Nm (1.0 mkg)
43 Nm
(4.3 mkg)
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Removing the oil pan and oil pump
Engine oil
Coolant
1
2
Radiator assembly and water pump
assembly
Exhaust pipe assembly
Oil level switch couplar
Oil level switch
1
1
4-53
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “RADIATOR” and “WATER
PUMP” in chapter 5.
Refer to “ENGINE”.
Disconnect.
OIL PAN AND OIL PUMP
ENG
10 Nm (1.0 mkg)
43 Nm
(4.3 mkg)
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
3
4
5
6
7
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
Oil strainer
1
1
1
2
1
8
9
10
11
12
13
Oil pipe
Oil delivery pipe
Gear cover
Dowel pin
Oil pump assembly
Relief valve assembly
1
1
1
2
1
1
Remarks
Refer to “REMOVEING/INSTALLING
THE OIL PAN.
Refer to “INSTALLING THE OIL
STRAINER”.
Refer to “INSTALLING THE OIL PUMP”.
For installation, reverse the removal
procedure.
4-54
OIL PAN AND OIL PUMP
ENG
EB411010
OIL PUMP
12 Nm (1.2 mkg)
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Remarks
Disassemble the parts in the order listed.
Disassemblying the oil pump
assembly
Oil pump rotor housing
Dowel pin
Oil pump inner rotor
Oil pump outer rotor
Dowel pin
Washer
Oil pump cover
Driver gear
1
2
1
1
1
1
1
1
For assembly reverse the disassembly
procedure.
4-55
OIL PAN AND OIL PUMP
ENG
EAS00362
REMOVING THE OIL PAN
1. Remove:
oil level switch 1
oil pan 2
oil pan gasket
dowel pins
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
EAS00364
CHECKING THE OIL PUMP
1. Check:
oil/pump driven gear 1
rotor housing 2
Cracks/damage/wear Replace the defective part(-s).
2. Measure:
inner-rotor-to-outer-rotor-tip clearance a
outer-rotor-to-oil-pump-cover clearance b
Out of specification Replace the oil pump.
1 Inner rotor
2 Outer rotor
3 Oil pump cover
Inner-rotor-to-outer-rotor-tip
clearance
0.03 0.09 mm <Limit>: 0.15
mm
Outer-rotor-to-oil-pump-cover
clearance
0.03 0.08 mm <Limit>: 0.15
mm
4-56
OIL PAN AND OIL PUMP
ENG
3. Check:
oil pump operation
Unsmooth Repair or replace the defective
part(-s).
EAS00365
CHECKING THE RELIEF VALVE
1. Check:
relief valve body 1
relief valve 2
spring 3
O-ring 4
Damage/wear Replace the defective
part(-s).
EAS00367
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:
oil delivery pipe 1
oil pipe 2
Damage Replace.
Obstruction Wash and blow out with compressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:
oil strainer 1
Damage Replace.
Contaminants Clean with engine oil.
EAS00373
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil
nozzles.
1. Check:
oil nozzle 1
O-ring 2
Damage/wear Replace the oil nozzle.
oil nozzle passage
Obstruction Blow out with compressed air.
4-57
OIL PAN AND OIL PUMP
ENG
EAS00375
ASSEMBLING THE OIL PUMP
1. Lubricate:
inner rotor
outer rotor
impeller shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Check:
oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
INSTALLING THE OIL PUMP
1. Install:
oil pump 1
12 Nm (1.2 mkg)
NOTE:
Install the oil pump assembly drive chain onto
the oil pump assembly driven sprocket.
EAS00378
INSTALLING THE OIL STRAINER
1. Install:
oil strainer 1
NOTE:
The arrow a on the oil strainer housing must
point towards the front of the engine.
EAS00380
INSTALLING THE OIL PAN
1. Install:
dowel pins
oil pan gasket New
12 Nm (1.2 mkg)
oil pan 1
2
oil level switch
10 Nm (1.0 mkg)
engine oil drain bolt 3
43 Nm (4.3mkg)
NOTE:
Tighten the oil pan bolts in stages and in a
crisscross pattern.
Lubricate the oil level switch O-ring with lithium
soap base grease.
4-58
CRANKCASE
ENG
CRANKCASE
12 Nm (1.2 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Refer to “SHIFT SHAFT”.
Refer to “PICKUP COIL AND PICKUP
ROTOR”.
Refer to ‘‘CLUTCH’’.
Refer to “WATER PUMP” in chapter 5.
Refer to “OIL PAN AND OIL PUMP”.
Separating the crankcase
Engine
Cylinder head
Starter clutch and generator
Shift shaft
Pickup coil and pickup rotor
Clutch assembly
Water pump assembly
Oil pan and oil pump
4-59
CRANKCASE
ENG
12 Nm (1.2 mkg)
Order
Job/Part
Q’ty
1
2
3
4
Timing chain
Oil pump drive chain guide
Oil pump drive chain
Lower crankcase
1
1
1
1
5
Dowel pin
3
Remarks
Refer to “DISASSEMBLY/ASSEMBLY
THE CRANKCASE”.
For installation, reverse the removal
procedure.
4-60
CRANKCASE
ENG
OIL BAFFLE PLATES AND OIL FILTER BOLT
80 Nm (8.0 mkg)
12 Nm (1.2 mkg)
12 Nm (1.2 mkg)
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the oil baffle plates and
oil filter bolt
Transmission
Oil baffle plate
Oil baffle plate
Oil delivery pipe
Bearing
Lower crankcase
Oil filter bolt
Upper crankcase
Refer to “TRANSMISSION”.
1
1
1
1
1
1
1
For instalation, reverse the removal
procedure.
4-61
CRANKCASE
ENG
EAS00384
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration).
The numbers embossed on the crankcase indicate the crankcase tightening sequence.
2. Remove:
crankcase bolts
3. Remove:
lower crankcase
CAUTION:
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure that the crankcase halves
separate evenly.
M8
M8
M8
M6
M6
M6
M6
85 mm bolts: 1 X 7 , 10
115 mm bolts: 8 , 9
65 mm bolts: 11 , 12
65 mm bolts: 13 , 14 , 17 , 27
55 mm bolts: 15 , 22 X 26
45 mm bolts: 16 , 19 X 21
75 mm bolt: 18
4. Remove:
dowel pins
4-62
CRANKCASE
ENG
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
upper crankcase
lower crankcase
Cracks/damage Replace.
oil delivery passages
Obstruction Blow out with compressed air.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement Replace.
2. Check:
oil seals
Damage/wear Replace.
CHECKING THE SPROCKETS AND CHAINS
1. Check:
crankshaft sprocket 1
oil/water pump assembly drive sprocket 2
Cracks/damage/wear Replace the defective part(-s).
2. Check:
timing chain 1
Damage/stiffness Replace the timing
chain and crankshaft sprocket as a set.
oil/water pump assembly drive chain 2
Damage/stiffness Replace the oil/water
pump assembly drive chain and oil/water
pump assembly drive sprocket as a set.
4-63
CRANKCASE
ENG
EAS00415
ASSEMBLING THE CRANKCASE
1. Lubricate:
crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:
sealant
(onto the crankcase mating surfaces and the
groove a of the oil baffle plate)
Yamaha bond No. 1215
90890-85505
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 3 mm of
the crankshaft journal bearings.
3. Install:
dowel pin
4. Set the shift drum assembly and transmission gears in the neutral position.
5. Install:
lower crankcase 1
(onto the upper crankcase 2 )
CAUTION:
Before tightening the crankcase bolts, make
sure that the transmission gears shift correctly when the shift drum assembly is
turned by hand.
4-64
CRANKCASE
ENG
6. Install:
crankcase bolts
NOTE:
Lubricate the bolt threads with engine oil.
Install a washer on bolts 1 X 10 .
Install a gasket on bolt 21 .
Not lubricate seal botts 18 12
Tighten the bolts in the tightening sequence
cast on the crankcase.
M8
M8
M8
M6
M6
M6
M6
85 mm bolts: 1 X 7 , 10
115 mm bolts: 8 , 9
65 mm bolts: 11 , 12
65 mm bolts: 13 , 14 , 17 , 27
55 mm bolts: 15 , 22 X 26
45 mm bolts: 16 , 19 X 21
75 mm bolt: 18
Bolt 15 X 27
12 Nm (1.2 mkg)
Bolt 13 X 14
14 Nm (1.4 mkg)
Bolt 1 X 12
24 Nm (2.4 mkg)
WARNING
Always use new copper washers.
4-65
CONNECTING RODS AND PISTONS
ENG
EAS00252
CONNECTING RODS AND PISTONS
15 Nm (1.5 mSkg)+90_
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the connecting rods and
pistons
Lower crankcase
1
2
3
4
5
6
7
Separate.
Refer to “CRANKCASE”.
4
4
4
8
4
4
4
Connecting rod cap
Big end lower bearing
Big end upper bearing
Piston pin clip
Piston pin
Piston
Connecting rod
4-66
Remarks
Refer to “REMOVING/INSTALLING THE
CONNECTING RODS AND PISTONS”.
CONNECTING RODS AND PISTONS
ENG
15 Nm (1.5 mSkg)+90_
Order
8
9
10
Job/Part
Q’ty
Remarks
4
4
4
Refer to “REMOVING/INSTALLING THE
CONNECTING RODS AND PISTONS”.
Top ring
2nd ring
Oil ring
For installation, reverse the removal
procedure.
4-67
CONNECTING RODS AND PISTONS
ENG
EAS00393
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:
connecting rod cap 1
big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
2. Remove:
piston pin clips 1
piston pin 2
piston 3
connecting rod
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
For reference during installation, put identification marks on the piston crown.
Before removing the piston pin, deburr the piston pin clip groove and the piston pin bore area
in the piston. If both areas are deburred and
the piston pin is still difficult to remove, remove
it with the piston pin puller 4 .
Piston pin puller
90890-01304
3. Remove:
top ring
2nd ring
oil ring
NOTE:
To remove a piston ring, open the end gap with
your fingers and lift the other side of the ring
over the piston crown.
4-68
ENG
CONNECTING RODS AND PISTONS
EAS00262
CHECKING THE CYLINDER AND PISTONS
The following procedure applies to all of the cylinders and pistons.
1. Check:
piston wall
cylinder wall
Vertical scratches Replace the crankcases, and the piston and piston rings as a
set.
2. Measure:
piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the
cylinder. Then, find the average of the measurements.
Cylinder bore gauge
90890-03017
Cylinder bore “C”
65.50 65.51 mm
Max. taper “T”
0.05 mm
Out of round “R”
0.05 mm
b. If out of specification, replace the crankcases, and the piston and piston rings as a
set.
c. Measure piston skirt diameter “P” with the
micrometer.
Micrometer
90890-03008
a 4 mm from the bottom edge of the piston
Piston size “P”
Standard
65.460 65.475 mm
d. If out of specification, replace the piston and
piston rings as a set.
4-69
CONNECTING RODS AND PISTONS
ENG
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.025 0.045 mm
<Limit>: 0.07 mm
f. If out of specification, replace the crankcases, and the pistons and piston rings as a
set.
EAS00263
CHECKING THE PISTON RINGS
1. Measure:
piston ring side clearance
Out of specification Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring side clearance
Top ring
0.030 0.065 mm
<Limit>: 0.115 mm
2nd ring
0.020 0.055 mm
<Limit>: 0.115 mm
2. Install:
piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the piston crown.
a 5 mm
4-70
CONNECTING RODS AND PISTONS
ENG
3. Measure:
piston ring end gap
Out of specification Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
Piston ring end gap
Top ring
0.15 0.25 mm
<Limit>: 0.50 mm
2nd ring
0.40 0.50 mm
<Limit>: 0.85 mm
Oil ring
0.10 0.35 mm
ABS00266
CHECKING THE PISTON PINS
The following procedure applies to all of the piston pins.
1. Check:
piston pin
Blue discoloration/grooves Replace the
piston pin and then check the lubrication system.
2. Measure:
piston pin outside diameter a
Out of specification Replace the piston
pin.
Piston pin outside diameter
15.991 16.000 mm
3. Measure:
piston pin bore diameter (in the piston)
Out of specification Replace the piston
pin.
Piston pin bore diameter
(in the piston)
16.002 16.013 mm
4-71
CONNECTING RODS AND PISTONS
ENG
4. Calculate:
piston-pin-to-piston-pin-bore clearance
Out of specification Replace the piston
pin.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter (in the piston)
–
Piston pin outside diameter
Piston-pin-to-piston-pin-bore
clearance
0.002 0.022 mm
<Limit>: 0.072 mm
CHECKING THE BIG END BEARINGS
1. Measure:
crankshaft-pin-to-big-end-bearing clearance
Out of specification Replace the big end
bearings.
Crankshaft-pin-to-big-endbearing clearance
0.028 0.052 mm
The following procedure applies to all of the
connecting rods.
CAUTION:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clearance
and prevent engine damage, the big end
bearings must be installed in their original
positions.
a. Clean the big end bearings, crankshaft pins,
and bearing portions of the connecting rods.
b. Install the big end upper bearing into the connecting rod and the big end lower bearing
into the connecting rod cap.
NOTE:
Align the projections a on the big end bearings
with the notches b in the connecting rod and
connecting rod cap.
4-72
CONNECTING RODS AND PISTONS
ENG
c. Put a piece of Plastigauge 1 on the crankshaft pin.
d. Assemble the connecting rod halves.
NOTE:
S Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.
S Lubricate the bolt threads and nut seats with
molybdenum disulfide grease.
S Make sure that the “Y” mark c on the connecting rod faces towards the left side of the crankshaft.
S Make sure that the characters d on both the
connecting rod and connecting rod cap are
aligned.
e. Tighten the connecting rod nuts.
CAUTION:
S When tightening the connecting rod nuts,
be sure to use an F-type torque wrench.
S After tightening the connecting rod nut to
the specified torque, turn the connecting
rod nut another+90_.
Refer to “INSTALLING THE PISTONS AND
CONNECTING RODS”.
Connecting rod nut
15 Nm (1.5 mSkg) + 90_
f. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS AND PISTONS”.
g. Measure the compressed Plastigauge
width e on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select replacement big end bearings.
4-73
CONNECTING RODS AND PISTONS
ENG
2. Select:
big end bearings (“P1” “P4”)
NOTE:
The numbers stamped into the crankshaft web
and the numbers on the connecting rods are
used to determine the replacement big end
bearing sizes.
“P1” “P4” refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod “P1” and
the crankshaft web “P1” numbers are “5” and
“1” respectively, then the bearing size for
“P1” is:
“P1” (connecting rod) – “P1” (crankshaft) =
5–1=4
BIG END BEARING COLOR CODE
1
blue
2
black
3
brown
4
green
EAS00271
INSTALLING THE PISTONS AND CONNECTING RODS
The following procedure applies to all of the pistons and cylinders.
1. Install:
top ring
2nd ring
oil ring
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
4-74
CONNECTING RODS AND PISTONS
ENG
2. Install:
piston 1
(onto the respective connecting rod 2 )
piston pin 3
piston pi clip 4 New
NOTE:
Apply engine oil onto the piston pin.
Make sure that the “Y” mark a on the connecting rod faces left when the arrow mark b on
the piston is pointing up. Refer to the illustration.
Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3. Offset:
piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
A Intake side
4. Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Lubricate:
bolt threads
nut seats
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide grease
4-75
CONNECTING RODS AND PISTONS
ENG
6. Lubricate:
S crankshaft pins
S big end bearings
S connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Install:
S big end bearings
S connecting rod assembly
(into the cylinder and onto the crankshaft
pin).
S connecting rod cap
(onto the connecting rod)
NOTE:
S Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.
S Be sure to reinstall each big end bearing in its
original place.
S While compressing the piston rings with one
hand, install the connecting rod assembly into
the cylinder with the other hand.
S Make sure that the “Y” marks a on the connecting rods face towards the left side of the
crankshaft.
S Make sure that the characters b on both the
connecting rod and connecting rod cap are
aligned.
8. Align:
S bolt heads
(with the connecting rod caps)
9. Tighten:
S connecting rod nuts
15 Nm (1.5 mSkg)+90_
a. Replace the connecting rod bolts and nuts
with new ones.
CAUTION:
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Always install new bolts and nuts.
4-76
CONNECTING RODS AND PISTONS
ENG
b. Clean the connecting rod bolts and nuts.
c. Tighten the connecting rod nuts.
d. Put a mark 1 on the corner of the connecting
rod nut 2 and the connecting rod 3 .
e. Tighten the nut further to reach the specified
angle (90_).
WARNING
When the nut is tightened more than the
specified angle, do not loosen the nut and
then retighten it.
Replace the bolt with a new one and perform
the procedure again.
CAUTION:
S Do not use a torque wrench to tighten the
nut to the specified angle.
S Tighten the nut until it is at the specified
angles.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60_.
4-77
CRANKSHAFT
ENG
EAS00381
CRANKSHAFT
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “CONNECTING RODS AND
PISTONS”.
Removing the crankshaft
Crankcase lower
Connecting rods and pistons
1
2
3
Remarks
1
5
5
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing
Refer to “REMOVING/INSTALLING
THE CRANKSHAFT”.
For installation, reverse the removal
procedure.
4-78
CRANKSHAFT
ENG
EAS00387
REMOVING THE CRANKSHAFT
1. Remove:
crankshaft 1
crankshaft journal upper bearings
(from the upper / lower crankcase)
NOTE:
Identify the position of each crankshaft journal
upper bearing so that it can be reinstalled in its
original place.
EAS00397
CHECKING THE CRANKSHAFT
1. Measure:
crankshaft runout
Out of specification Replace the crankshaft.
Max. crankshaft runout
0.03 mm
2. Check:
crankshaft journal surfaces
crankshaft pin surfaces
bearing surfaces
Scratches/wear Replace the crankshaft.
CHECKING THE CRANKSHAFT JOURNAL
BEARINGS
1. Measure:
crankshaft-journal-to-crankshaft-journalbearing clearance
Out of specification Replace the crankshaft journal bearings.
Crankshaft-journal-to-crankshaftjournal-bearing clearance
0.034 0.058 mm
CAUTION:
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing
clearance and prevent engine damage, the
crankshaft journal bearings must be
installed in their original positions.
4-79
CRANKSHAFT
ENG
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions of
the crankcase.
b. Place the upper crankcase upside down on a
bench.
c. Install the crankshaft journal upper bearings
1 and the crankshaft into the upper crankcase.
NOTE:
Align the projections a on the crankshaft journal upper bearings with the notches b in the
upper crankcase.
d. Put a piece of Plastigauge 2 on each
crankshaft journal.
NOTE:
Do not put the Plastigauge over the oil hole in
the crankshaft journal.
e. Install the crankshaft journal lower bearings
into the lower crankcase and assemble the
crankcase.
NOTE:
Align the projections a on the crankshaft journal lower bearings with the notches b in the
lower crankcase.
Do not move the crankshaft until the clearance
measurement has been completed.
f. Tighten the bolts to specification in the tightening sequence cast on the crankcase.
Bolt 15 27
12 Nm (1.2 mkg)
Bolt 13 14
14 Nm (1.4 mkg)
Bolt 1 12
24 Nm (2.4 mkg)
NOTE:
Lubricate the crankcase bolt threads with engine oil.
4-80
CRANKSHAFT
ENG
g. Remove the lower crankcase and the crankshaft journal lower bearings.
h. Measure the compressed Plastigauge
width c each crankshaft journal.
If the clearance is out of specification, select
replacement crankshaft journal bearings.
2. Select:
crankshaft journal bearings (J1 J5)
NOTE:
The numbers stamped into the crankshaft web
and the numbers stamped into the lower
crankcase are used to determine the replacement crankshaft journal bearing sizes.
“J1” “J5” refer to the bearings shown in the
crankshaft illustration.
If “J1” “J5” are the same, use the same size
for all of the bearings.
For example, if the crankcase “J1” and crankshaft web “J1” numbers are “6” and “2” respectively, then the bearing size for “J1” is:
Bearing size for J1:
“J1” (crankcase) – “J1” (crankshaft
web) – 1=
6–2–1=3
J1 J2 J3 J4 J5
CRANKSHAFT JOURNAL BEARING
COLOR CODE
0
White
1
Blue
2
Black
3
Brown
4
Green
NOTE:
If the size is the same for all “J1 to J5”, one digit
for that size is indicated. (crankcase side only)
4-81
CRANKSHAFT
ENG
EAS00407
INSTALLING THE CRANKSHAFT
1. Install:
crankshaft journal upper bearings
(into the upper / lower crankcase)
NOTE:
Align the projections a on the crankshaft journal upper bearings with the notches b in the
upper crankcase.
Be sure to install each crankshaft journal upper bearing in its original place.
4-82
TRANSMISSION
ENG
EAS00419
TRANSMISSION
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “SHIFT SHAFT”.
Removing the transmission
Crankcase lower
1
2
3
4
5
6
Remarks
Shift shaft and stopper lever
Drive axle assembly
Circlip
Oil seal
Bearing
Shift bar stopper
Shift fork guide bar
1
1
1
1
1
2
4-83
TRANSMISSION
ENG
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
Order
7
8
9
10
11
12
Job/Part
Q’ty
4
1
1
1
1
1
Spring
Shift fork “L”
Shift fork “R”
Shift drum assembly
Shift fork “C”
Main axle assembly
Remarks
Refer to “INSTALLING THE
TRANSMISSION”.
Refer to “REMOVING THE
TRANSMISSION”.
For installation, reverse the removal
procedure.
4-84
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
ENG
Remarks
Remove the parts in the order listed.
Disassembling the main axle
assembly
Bearing
2nd pinion gear
Toothed lock washer
Toothed lock washer retainer
6th pinion gear
Collar
Washer
Circlip
3rd pinion gear
Circlip
1
1
1
1
1
1
1
1
1
1
4-85
TRANSMISSION
Order
11
12
13
14
15
16
Job/Part
Q’ty
ENG
Remarks
1
1
1
1
1
1
Washer
5th pinion gear
Collar
Main axle
Bearing housing
Bearing
For installation, reverse the removal
procedure.
4-86
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Q’ty
ENG
Remarks
Remove the parts in the order listed.
Disassembling the drive axle
assembly
Washer
1st wheel gear
Collar
5th wheel gear
Circlip
Washer
3rd wheel gear
Collar
Toothed lock washer
Toothed lock washer retainer
4th wheel gear
1
1
1
1
1
1
1
1
1
1
1
4-87
TRANSMISSION
Order
12
13
14
15
16
17
18
19
20
21
22
23
24
Job/Part
Q’ty
ENG
Remarks
1
1
1
1
1
1
1
1
1
1
1
1
1
Collar
Washer
Circrip
6th wheel gear
Circrip
washer
2nd wheel gear
Collar
Collar
Oil seal
Bearing
Circrip
Drive axle
For installation, reverse the removal
procedure.
4-88
TRANSMISSION
ENG
EAS00420
REMOVING THE TRANSMISSION
1. Remove:
drive axle assembly
2. Remove:
main axle assembly 1
(with the Torx wrench T30)
a. Insert two bolts 2 of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing.
b. Tighten the bolts until they contact the crankcase surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.
EAS00421
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift
forks.
1. Check:
shift fork cam follower 1
shift fork pawl 2
Bends/damage/scoring/wear Replace the shift fork.
2. Check:
shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
4-89
TRANSMISSION
ENG
3. Check:
shift fork movement
(along the shift fork guide bar)
Rough movement Replace the shift
fork(-s) and shift fork guide bar as a set.
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
shift drum grooves
Damage/scratches/wear Replace the
shift drum assembly.
shift drum segment 1
Damage/wear Replace the shift drum assembly.
shift drum bearing 2
Damage/pitting Replace the shift drum
assembly.
EAS00425
CHECKING THE TRANSMISSION
1. Measure:
main axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the main
axle.
Max. main axle runout
0.02 mm
2. Measure:
drive axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the drive
axle.
Max. drive axle runout
0.02 mm
3. Check:
transmission gears
Blue discoloration/pitting/wear Replace the defective gear(-s).
transmission gear dogs
Cracks/damage/rounded edges Replace the defective gear(-s).
4-90
TRANSMISSION
ENG
4. Check:
transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect Reassemble the transmission
axle assemblies.
5. Check:
transmission gear movement
Rough movement Replace the defective
part(-s).
6. Check:
circlips
Bends/damage/looseness Replace.
INSTALLING THE TRANSMISSION
1. Install:
main axle assembly
shift fork “C”
shift drum assembly
shift fork “R”
shift fork “L”
springs
shift fork guide bars
drive axle assembly
NOTE:
Carefully position the shift forks so that they
are installed correctly into the transmission
gears.
Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.
Make sure that the drive axle bearing circlip is
inserted into the grooves in the upper crankcase.
2. Check:
transmission
Rough movement Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
4-91
ENG
COOL
5
COOL
CHAPTER 5.
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CHECKING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
INSTALLING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13
5-15
5-15
5-16
COOL
RADIATOR
COOL
COOLING SYSTEM
RADIATOR
9 Nm (0.9 mkg)
7 Nm (0.7 mkg)
28 Nm (2.8 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “AIRFILTER CASE AND IGNITION COILS” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Removeing the radiator
Rider seat and fuel tank
Air filter case and heat protector plate
1
2
3
Remarks
Bottom cowling and side cowlings
Coolant
Coolant reserver hose
Breather hose
Radiator outlet hose
1
2
1
5-1
Disconnect.
RADIATOR
COOL
9 Nm (0.9 mkg)
7 Nm (0.7 mkg)
28 Nm (2.8 mkg)
Order
4
5
6
7
8
9
Job/Part
Q’ty
1
1
1
1
1
1
Radiator inlet hose
Oil cooler outlet hose
Thermo switch coupler
Radiator fan motor coupler
Radiator
Radiator fan
Remarks
Disconnect.
Disconnect.
Disconnect.
For installation reverse the removal
procedure.
5-2
RADIATOR
COOL
EAS00455
CHECKING THE RADIATOR
1. Check:
radiator fins
Obstruction Clean.
Apply compressed air to the rear of the radiator.
Damage Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flathead screwdriver.
2. Check:
radiator hoses
Cracks/damage Replace.
3. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Radiator cap opening pressure
110 140 kPa
(1.1 1.4 kg/cm2, 1.1 1.4 bar)
a. Install the radiator cap tester 1 and adapter
2 onto the radiator cap 3 .
Radiator cap tester
90890-01325
Adapter
90890-01352
b. Apply the specified pressure for ten seconds
and make sure that there is no drop in pressure.
4. Check:
radiator fan
Damage Replace.
Malfunction Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
5-3
RADIATOR
COOL
EAS00456
INSTALLING THE RADIATOR
1. Fill:
cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
cooling system
Leaks Repair or replace any faulty part.
3. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
5-4
OIL COOLER
COOL
EAS00457
OIL COOLER
63 Nm (6.3 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “RADIATOR”.
Refer to “ENGINE” in chapter 4.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Removing the oil cooler
Radiator assembly
Exaust pipe assembly
Engine oil
1
2
3
4
Remarks
1
1
1
1
Oil cooler outlet hose
Bolt
Washer
Oil cooler
5-5
Refer to “INSTALLING THE OIL
COOLER”.
OIL COOLER
COOL
63 Nm (6.3 mkg)
Order
5
6
7
8
9
10
Job/Part
Q’ty
Remarks
1
1
1
1
1
1
Oil cooler inlet hose
Water jacket joint
Water jacket joint hose
Water pump outlet pipe
Water pump outlet hose
Water pump inlet hose
For installation, reverse the removal
procedure.
5-6
OIL COOLER
COOL
EAS00458
CHECKING THE OIL COOLER
1. Check:
oil cooler
Cracks/damage Replace.
2. Check:
oil cooler inlet hose
oil cooler outlet hose
Cracks/damage/wear Replace.
3. Check:
water jacket joint
water jacket joint inlet hose
water pump outlet hose
Cracks/damage Replace.
EBS00459
INSTALLING THE OIL COOLER
1. Clean:
mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
O-ring New
oil cooler 1
washer 2 New
bolt 3
63 Nm (6.3 mkg)
NOTE:
Before installing the oil cooler, lubricate the oil
cooler bolt and O-ring with a thin coat of engine
oil.
Make sure that the O-ring is positioned properly.
Align the projection a on the oil cooler with the
slot b in the crankcase.
3. Bend the lock washer tab along a flat side of
the bolt.
5-7
OIL COOLER
COOL
4. Fill:
cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
crankcase
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
5. Check:
cooling system
Leaks Repair or replace any faulty part.
6. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
5-8
THERMOSTAT
COOL
THERMOSTAT
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEAT” and “FUEL TANK” in
chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “AIRFILTER CASE AND
IGNITION COILS” in chapter 3.
Refer to “CARBURETORS” in chapter 6.
Removing the termostat
Rider seat and fuel tank
Coolant
Air filter case
Carburetor assembly
5-9
THERMOSTAT
Order
1
2
3
4
Job/Part
Q’ty
Radiator inlet hose
Carburator outlet hose
Thermostat cover
Thermostat
1
1
1
1
5-10
COOL
Remarks
Refer to “INSTALLING THE
THERMOSTAT
For installation, revers the removal
procedure.
THERMOSTAT
COOL
EAS00462
CHECKING THE THERMOSTAT
1. Check:
S thermostat 1
Does not open at 71 84_C Replace.
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
1 Thermostat
2 Thermometer
3 Water
4 Container
A Fully closed
B Fully opens
Opening (mm)
NOTE:
If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious
overheating or overcooling.
2. Check:
S thermostat housing cover
S thermostat housing
Cracks/damage Replace.
84
Temperature
EB00467
INSTALLING THE THERMOSTAT
1. Install:
NOTE:
Install the thermostat with its breather hole a
facing up.
2. Install
S thermostat cover
10 Nm (1.0 mSkg)
NOTE:
Befor installing the thermostat cover to the cylinder head, lubricate the O-ring with a thin coat
of litium soap base grease.
5-11
THERMOSTAT
COOL
3. Fill:
coolling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
4. Check:
cooling system
Leaks Repair or replace any faulty part.
5. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
5-12
WATER PUMP
COOL
WATER PUMP
12 Nm (1.2 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Removing the water pump assembly
Coolant
1
2
3
4
5
Remarks
1
1
1
1
1
Water pump inlet hose
Water pump outlet hose
Water pump hose
Clutch wire and holder
Water pump
For installation, reverse the removal
procedure.
5-13
WATER PUMP
COOL
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
Disassembling the water pump
assembly
Water pump cover
O-ring
Impeller shaft (along with the impeller)
Water pump seal
Oil seal
Bearing
Circlip
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
Refer to “DISASSEMBLING/
ASSEMBLING THE WATER PUMP”.
For assembly, reverse the disassembly
procedure.
5-14
WATER PUMP
COOL
EAS00470
DISASSEMBLING THE WATER PUMP
1. Remove:
water pump seal 1
NOTE:
Tap out the water pump seal from the inside of
the water pump housing.
2 Water pump housing
2. Remove:
oil seal 1
circlip
bearing 2
NOTE:
Tap out the bearing and oil seal from the outside
of the water pump housing.
3 Water pump housing
3. Remove:
rubber damper holder 1
rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
NOTE:
Do not scratch the impeller shaft.
EAS00474
CHECKING THE WATER PUMP
1. Check:
water pump housing cover 1
water pump housing 2
impeller 3
rubber damper 4
rubber damper holder 5
Cracks/damage/wear Replace.
2. Check:
water pump seal
oil seal
Cracks/damage/wear Replace.
bearing
Rough movement Replace.
5-15
WATER PUMP
COOL
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
bearing
oil seal 1 New
(into the water pump housing 2 )
NOTE:
Before installing the oil seal, apply tap water or
coolant onto its outer surface.
Install the oil seal with a socket that matches
its outside diameter.
2. Install:
water pump seal 1 New
CAUTION:
Never lubricate the water pump seal surface
with oil or grease.
NOTE:
Install the water pump seal with the special
tools.
Before installing the water pump seal, apply
Yamaha bond No.1215 2 to the water pump
housing 3 .
Mechanical seal installer
90890-04078 4
Middle driven shaft bearing
driver 5
90890-04058 5
Yamaha bond No. 1215
90890-85505
A Push down.
3. Install:
rubber damper 1 New
rubber damper holder 2 New
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
5-16
WATER PUMP
COOL
4. Measure:
impeller shaft tilt
Out of specification Repeat steps (3) and
(4).
CAUTION:
Make sure that the rubber damper and rubber damper holder are flush with the impeller.
Max. impeller shaft tilt
0.15 mm
1 Straightedge
2 Impeller
5-17
COOL
CARB
6
CARB
CHAPTER 6.
CARBURETORS
CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL COCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL COCK OPERATION . . . . . . . . . . . . . . . . . . .
6-1
6-7
6-9
6-11
6-12
6-13
6-16
6-17
6-17
CARB
CARBURETORS
CARB
EAS00481
CARBURETORS
CARBURETORS
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “Seats” and “FUEL TANK” in
chapter 3.
Refer to “AIR FILTER CASE AND
IGNITION COILS” in chapter 3.
Removing the carburetors
Rider seat and fuel tank
Air filter case and heat protector plate
1
2
3
4
Remarks
1
1
1
1
Starter cable
Fuel hose
Throttle position sensor coupler
Throttle stop screw
6-1
Disconnect
CARBURETORS
Order
5
6
7
8
9
10
Job/Part
Q’ty
CARB
Remarks
2
4
2
1
4
2
Therm bypass hose
Carburetor joint clamp screw
Throttle cable
Carburetor assembly
Carburetor joint
Side cover
For installation, reverse the removal
procedure.
6-2
CARBURETORS
Order
Job/Part
Q’ty
CARB
Remarks
Remove the parts in the order listed.
1
2
3
4
5
Separating the carburetors
Starter plunger link
Connecting bolt
Connecting bolt
Hose joint
Spring
1
1
1
2
2
6
7
8
9
10
11
Fuel feed pipe
Fuel feed pipe
Pipe
Throttle stop screw
Throttle position sensor
Water pipe
2
1
2
1
1
2
6-3
Refer to “ASSEMBLING THE
CARBURETORS”
Refer to “ASSEMBLING THE
CARBURETORS”
CARBURETORS
Order
12
13
14
15
Job/Part
Q’ty
Balance pipe
Balance pipe bracket
Throttle cable bracket
Carburetor
CARB
Remarks
2
1
1
4
For installation, reverse the removal
procedure
6-4
CARBURETORS
Order
Job/Part
Q’ty
10
11
Remarks
Disassemble the parts in the order listed.
NOTE:
The following procedure applies to all of
the carburetors.
Disassembling the carburetor
1
2
3
4
5
6
7
8
9
CARB
1
1
1
1
1
1
1
1
1
1
1
Starter plunger
Air funnel
Vacuum chamber cover
Piston valve spring
Jet needle holder
Jet needle kit
Piston valve
Pilot screw
Fuel drain bolt
Float chamber
Float pivot pin
6-5
Refer to “ASSEMBLING THE
CARBURETORS.”
CARBURETORS
Order
12
13
14
15
16
Job/Part
Q’ty
CARB
Remarks
1
1
1
1
1
Float
Needle valve
Main jet
Main jet holder
Pilot jet
For assembly, reverse the disassembly
procedure.
6-6
CARBURETORS
CARB
EAS00486
CHECKING THE CARBURETORS
The following procedure applies to all of the carburetors.
1. Check:
carburetor body
float chamber
Cracks/damage Replace.
2. Check:
fuel passages
Obstruction Clean.
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
3. Check:
float chamber body
Dirt Clean.
4. Check:
float chamber rubber gasket 1
Cracks/damage/wear Replace.
5. Check:
float
Damage Replace.
6. Check:
needle valve 1
Damage/obstruction/wear Replace the
needle valve, needle valve seat and O-ring
as a set.
6-7
CARBURETORS
CARB
7. Check:
piston valve 1
Damage/scratches/wear Replace.
piston valve diaphragm 2
Cracks/tears Replace.
8. Check:
vacuum chamber cover 1
piston valve spring 2
jet needle holder 3
Cracks/damage Replace.
9. Check:
jet needle kit 1
main jet 2
main jet holder 3
pilot jet 4
pilot screw 5
starter plunger 6
Bends/damage/wear Replace.
Obstruction Clean.
Blow out the jets with compressed air.
10. Check:
piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness Replace the piston valve.
11. Check:
fuel feed pipes 1
pipes 2
hose joint 3
Cracks/damage Replace.
Obstruction Clean.
Blow out the pipes with compressed air.
6-8
CARBURETORS
CARB
12. Check:
fuel hoses
Cracks/damage/wear Replace.
Obstruction Clean.
Blow out the hoses with compressed air.
EAS00490
ASSEMBLING THE CARBURETORS
The following procedure applies to all of the carburetors.
CAUTION:
Before assembling the carburetors, wash
all of the parts in a petroleumbased solvent.
Always use a new gasket.
1. Install:
pilot screw kit 1
Pilot screw setting
2 turns out
2. Install:
piston valve 1
jet needle
jet needle holder
piston valve spring
vacuum chamber cover
NOTE:
Install the end of the piston valve spring onto
the spring guide on the vacuum chamber cover.
Align the tab a on the piston valve diaphragm
with the recess b in the carburetor body.
6-9
CARBURETORS
CARB
3. Install:
pipes
fuel feed pipes
vacuum chamber pipe
vacuum chamber air vent hose
springs
float chamber air vent hoses
hose joint
spacers
copper washer
connecting bolts
NOTE:
Do not tighten the connecting bolts yet.
Install the throttle valve lever 1 onto carburetors #2, #3, and #4 between the spring 2 and
synchronizing screw 3 .
4. Install:
starter plunger link 1
NOTE:
Install the starter plunger link 1 onto each starter plunger.
5. Tighten:
connecting bolts
7 Nm (0.7 mkg)
NOTE:
Place the carburetor assembly on a surface
plate with the intake manifold side down.
Then, tighten the connecting bolts while pushing down the carburetor assembly with an
even force.
After tightening the connecting bolts, check
that the throttle valve lever and starter plunger
link operate smoothly.
6. Install:
starter cable 1
NOTE:
Install the starter cable holder 2 onto the starter cable.
6-10
CARBURETORS
CARB
EAS00493
INSTALLING THE CARBURETORS
1. Adjust:
carburetor synchronization
Refer to “SYNCHRONIZING THE CARBURETORS” in chapter 3.
2. Adjust:
engine idling speed
Engine idling speed
1250 1350 r/min
Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3.
3. Adjust:
throttle cable free play
Throttle cable free play (at the
flange of the throttle grip)
6 8 mm
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
6-11
CARBURETORS
CARB
EAS00497
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
fuel level a
Out of specification Adjust.
Fuel level (below the mark on
the body)
17.5 18.5 mm
a. Stand the motorcycle on a level surface.
b. Place the motorcycle on a suitable stand to
ensure that the motorcycle is standing
straight up.
c. Install the fuel level gauge 1 onto the fuel
drain pipe 2 .
Fuel level gauge
90890-01312
d. Loosen the fuel drain bolt 3 .
e. Hold the fuel level gauge vertically next to the
line 4 on the float chamber.
f. Measure the fuel level a .
NOTE:
Fuel level readings should be equal on both
sides of the carburetor assembly.
2. Adjust:
fuel level
a. Remove the carburetor assembly.
b. Check the needle valve seat and needle
valve.
c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by slightly bending the float tang 1 .
e. Install the carburetor assembly.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is
within specification.
6-12
CARBURETORS
CARB
EAS00502
CHECKING AND ADJUSTING THE THROTTLE
POSITION SENSOR
NOTE:
Before adjusting the throttle position sensor, the
engine idling speed should be properly adjusted.
1. Check:
S throttle position sensor
(installed on the carburetor)
a. Disconnect the throttle position sensor coupler.
b. Connect the pocket tester (Ω
1k) to the
throttle position sensor.
Tester positive probe blue 1
Tester negative probe black/blue 2
c. Measure the throttle position sensor maximum resistance.
Out of specification Replace the throttle
position sensor.
Throttle position sensor maximum
resistance
4.0 X 6.0 kΩ at 20_C
(blue – black/blue)
d. Connect the pocket tester (Ω
throttle position sensor.
1k) to the
Tester positive probe yellow 3
Tester negative probe black/blue 2
e. While slowly opening the throttle, check that
the throttle position sensor resistance is
within the specified range.
NOTE:
Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those specified.
Out of specification or the resistance changes
abruptly Go to step (2).
Throttle position sensor resistance
0 X 5 ± 1.0 kΩ at 20_C
(yellow – black/blue)
6-13
CARBURETORS
CARB
2. Check:
S throttle position sensor
(removed from the carburetor)
a. Disconnect the throttle position sensor coupler.
b. Remove the throttle position sensor from the
carburetor.
c. Connect the pocket tester (Ω
1k) to the
throttle position sensor.
Tester positive probe blue 1
Tester negative probe black/blue 2
d. Measure the throttle position sensor maximum resistance.
Out of specification Replace the throttle
position sensor.
Throttle position sensor maximum resistance
4.0 X 6.0 kΩ at 20_C
(blue – black/blue)
e. Connect the pocket tester (Ω
throttle position sensor coupler.
1k) to the
Tester positive probe yellow 3
Tester negative probe black/blue 2
f. While slowly opening the throttle, check that
the throttle position sensor resistance is
within the specified range.
The resistance does not change or it changes
abruptly Replace the throttle position sensor.
The slot is worn or broken Replace the
throttle position sensor.
NOTE:
Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those specified.
Throttle position sensor resistance
0 X 5 ± 1.0 kΩ at 20_C
(yellow – black/blue)
6-14
CARBURETORS
CARB
3. Adjust:
throttle position sensor angle
a. Set the main switch to “ON”.
b. Disconnect the throttle position sensor coupler.
c. Reconnect the throttle position sensor coupler.
NOTE:
After reconnecting the throttle position sensor
coupler, the tachometer switches to the throttle
position sensor adjustment mode.
d. Loosen the throttle position sensor screws
1.
e. Adjust the throttle position sensor angle according to the following table.
NOTE:
The angle of the throttle position sensor is indicated by the r/min which are displayed on the
tachometer.
Tachometer
Reading
5000 rpm 2
Throttle posi- Adjustment
tion sensor
direction
angle
Correct
–
0 rpm
Incorrect
a
10000 rpm
Incorrect
b
f. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
NOTE:
To exit the throttle position sensor adjustment
mode, start the engine or set the main switch to
“OFF”.
6-15
CARBURETORS
CARB
EAS00504
CHECKING THE FUEL PUMP
1. Check:
fuel pump 1
a. Remove the fuel tank.
Refer to “FUEL TANK” in chapter 3.
b. Disconnect the fuel-pump-to-carburetor fuel
hose 2 from the carburetor.
c. Connect the fuel-tank-to-fuel-pump fuel
hose to the fuel tank and then set the fuel
cock to “ON”.
d. Place a container under the end of the fuel
hose 2 .
e. Start the engine and check if fuel flows from
the fuel hose 2 .
Fuel flows.
Fuel pump is OK.
Fuel does not
flow.
Replace
p
the fuel
pump.
f. Stop the engine and check if the fuel stops
flowing from the fuel hose 2 .
6-16
Fuel stops flowing.
Fuel pump is OK.
F el flows.
Fuel
flows
Replace
p
the fuel
pump.
CARBURETORS
CARB
EAS00505
CHECKING THE FUEL COCK
1. Remove
fuel tank
fuel filter 1
fuel cock 2
2. Check:
fuel cock
Cracks/damage/wear Replace.
3. Check:
fuel cock strainer 1
(with compressed air)
Dirt/obstruction Clean.
Damage Replace.
4. Install
fuel cock
fuel filter
fuel tank
EAS00506
CHECKING THE FUEL COCK OPERATION
NOTE:
After installing the fuel cock, check its operation.
1. Check that the fuel cock lever is turned to
“ON” or “OFF”.
2. Place a container under the end of the fuel
hose.
3. Check:
fuel cock operation
a. Suck on the end of the vacuum hose.
Fuel flows.
Fuel cock is OK.
Fuel does not flow.
Replace the fuel cock.
6-17
CARB
CHAS
7
CHAS
CHAPTER 7.
CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . .
7-1
7-3
7-3
7-5
7-6
7-6
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET . . . .
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE DISC AND REAR WHEEL SPROCKET . . . . . . . . . . . . . . . . .
REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .
INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . .
7-8
7-8
7-9
7-11
7-11
7-12
7-12
7-13
7-13
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER AND BRAKE FLUID
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . .
REMOVING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . .
INSTALLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . .
FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . .
REMOVING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . . . .
INSTALLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . .
INSTALLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . .
7-14
7-14
7-15
7-16
7-18
7-21
7-24
7-26
7-26
7-26
7-27
7-29
7-31
7-33
7-35
7-36
7-37
7-38
7-40
CHAS
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . .
7-42
7-45
7-45
7-47
7-48
7-53
HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-54
7-56
7-56
7-57
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
7-59
7-59
7-61
7-61
7-62
REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLING THE REAR SHOCK ABSORBER AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . .
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RELAY ARM AND CONNECTING ARM . . . . . . . .
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . .
7-64
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-68
7-70
7-70
7-71
7-73
7-75
7-75
7-65
7-65
7-66
7-66
7-67
7-67
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
6 Nm (0.6 mkg)
72 Nm (7.2 mkg)
20 Nm (2.0 mkg)
40 Nm (4.0 mkg)
18 Nm (1.8 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the front wheel and brake
discs
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
1
2
3
4
5
6
7
2
2
1
1
1
2
2
Brake hose holders (left and right)
Brake calipers (left and right)
Wheel axle pinch bolt
Front wheel axle
Front wheel
Collars (left and right)
Brake discs (left and right)
Refer to “INSTALLING THE FRONT
WHEEL”.
Loosen
Refer to “REMOVING/INSTALLING THE
FRONT WHEEL”.
For installation, reverse the removal
procedure.
7-1
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00518
Order
1
2
3
Job/Part
Q’ty
Disassembling the front wheel
Oil seals (left and right)
Wheel bearings (left and right)
Spacer
Remarks
Remove the parts in the order listed.
2
2
1
For assembly, reverse the disassembly
procedure.
7-2
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00521
REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove:
Brake hose holders
left brake caliper
right brake caliper
wheel axle
NOTE:
Do not squeeze the brake lever when removing
the brake calipers.
3. Elevate:
front wheel
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
EAS00525
CHECKING THE FRONT WHEEL
1. Check:
wheel axle
Roll the wheel axle on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
tire
front wheel
Damage/wear Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
7-3
FRONT WHEEL AND BRAKE DISCS
CHAS
3. Measure:
radial wheel runout 1
lateral wheel runout 2
Over the specified limits Replace.
Front radial wheel runout
1.0 mm
Front lateral wheel runout
0.5 mm
4. Check:
wheel bearings
Front wheel turns roughly or is loose Replace the wheel bearings.
oil seals
Damage/wear Replace.
5. Replace:
wheel bearings New
oil seals New
a. Clean the outside of the front wheel hub.
b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
c. Remove the wheel bearings 3 with a general bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing center
race 4 or balls 5 . Contact should be made
only with the outer race 6
NOTE:
Use a socket 7 that matches the diameter of
the wheel bearing outer race and oil seal.
7-4
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00533
CHECKING THE BRAKE DISCS
The following procedure applies to both of the
brake discs.
1. Check:
brake disc
Damage/galling Replace.
2. Measure:
brake disc deflection
Out of specification Correct the brake disc
deflection or replace the brake disc.
Max. brake disc deflection
Front: 0.1 mm
Rear: 0.1 mm
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebars to the left or
right to ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm below the
edge of the brake disc.
3. Measure:
brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
Min. brake disc thickness
Front: 4.5 mm
Rear: 4.5 mm
4. Adjust:
brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
7-5
FRONT WHEEL AND BRAKE DISCS
CHAS
Brake disc bolt
18 Nm (1,8 mkg)
LOCTITE
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
EAS00545
INSTALLING THE FRONT WHEEL
1. Lubricate:
wheel axle
oil seal lips
Recommended lubricant
Lithium soap base grease
2. Tighten:
wheel axle 1
wheel axle pinch bolt 2
72 Nm (7.2 mkg)
20 Nm (2,0 mkg)
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebars several times
and check if the front fork rebounds
smoothly.
3. Install:
brake calipers
brake hose holders
40 Nm (4.0 mkg)
WARNING
Make sure that the brake hose is routed
properly.
EAS00549
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
Adjust the front wheel static balance with the
brake discs installed.
7-6
FRONT WHEEL AND BRAKE DISCS
CHAS
1. Remove:
S balancing weight(-s)
2. Find:
S front wheel’s heavy spot
a. Place the front wheel on a suitable balancing
stand.
b. Spin the front wheel.
c. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
d. Turn the front wheel 90_ so that the “X1” mark
is positioned as shown.
e. Release the front wheel.
f. When the front wheel stops, put an “X2” mark
at the bottom of the wheel.
g. Repeat steps (a) through (d) several times
until all the marks come to rest at the same
spot.
h. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
3. Adjust:
S front wheel static balance
a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.
b. Turn the front wheel 90_ so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that position, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
4. Check:
S front wheel static balance
a. Turn the front wheel and make sure that it
stays at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
7-7
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EAS00550
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET
REAR WHEEL
40 Nm (4.0 mkg)
150 Nm (15 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
Removing the rear wheel
1
2
3
4
5
6
7
8
9
10
11
Remarks
1
2
2
1
1
1
1
1
1
1
1
Brake caliper
Locknuts (left and right)
Adjusting bolts (left and right)
Wheel axle nut
Washer
Rear wheel axle
Left adjusting block
Right adjusting block
Rear wheel
Brake caliper bracket bolt
Brake caliper bracket
Loosen.
Loosen.
NOTE:
Make sure that the tapered side of the right
adjusting block faces the wheel.
For installation, reverse the removal
procedure.
7-8
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EAS00556
BRAKE DISC AND REAR WHEEL SPROCKET
18 Nm (1.8 mkg)
69 Nm (6.9 mkg)
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the brake disc and rear
wheel sprocket
Brake disc
Rear wheel sprocket
Spacers (left and right)
Oil seal
Bearing
Rear wheel drive hub
Rear wheel drive hub dampers
Rear wheel
1
1
2
1
1
1
5
1
For installation, reverse the removal
procedure.
7-9
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
Order
1
2
3
4
5
6
Job/Part
Q’ty
CHAS
Remarks
Disassemble the parts in the order listed.
Disassembling the rear wheel
Spacer
Bearing
Spacer
Oil seal
Circlip
Bearing
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
7-10
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EAS00561
REMOVING THE REAR WHEEL
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
brake caliper
NOTE:
Do not depress the brake pedal when removing
the brake caliper.
3. Remove:
wheel axle nut
washer
wheel axle
adjusting blocks
brake caliper bracket.
rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
EAS00565
CHECKING THE REAR WHEEL
1. Check:
wheel axle
rear wheel
wheel bearings
oil seals
brake disc
Refer to “BRAKE DISC AND REAR WHEEL
SPROKET”.
2. Check:
tire
rear wheel
Damage/wear Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
7-11
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
3. Measure:
radial wheel runout
lateral wheel runout
Refer to “FRONT WHEEL”.
Over the specified limits Replace.
Max. radial wheel runout
1.0 mm
Max. lateral wheel runout
0.5 mm
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
rear wheel drive hub 1
Cracks/damage Replace.
rear wheel drive hub dampers 2
Damage/wear Replace.
EAS00568
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
rear wheel sprocket
More than 1/4 tooth a wear Replace the
rear wheel sprocket.
Bent teeth Replace the rear wheel sprocket.
b Correct
1 Drive chain roller
2 Rear wheel sprocket
2. Replace:
rear wheel sprocket
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket self-locking
nut
69 Nm (6.9 mkg)
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
7-12
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
CHAS
EAS00571
INSTALLING THE REAR WHEEL
1. Lubricate:
wheel axle
wheel bearings
oil seal lips
Recommended lubricant
Lithium soap base grease
2. Install:
rear wheel
brake caliper bracket
adjusting blocks
wheel axle
washer
wheel axle nut
brake caliper
3. Adjust:
drive chain slack a
Drive chain slack
40 50 mm
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
4. Tighten:
wheel axle nut
brake caliper bolts
150 Nm (15.0 mkg)
27 Nm (2.7 mkg)
WARNING
Make sure that the brake hose is routed
properly.
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
rear wheel static balance
Refer to “FRONT WHEEL”.
7-13
FRONT AND REAR BRAKES
CHAS
EAS00577
FRONT AND REAR BRAKES
FRONT BRAKE PADS
40 Nm (4.0 mkg)
Order
6 Nm (0.6 mkg)
Job/Part
Q’ty
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Removing the front brake pads
1
2
3
4
5
6
Remarks
2
1
1
2
2
1
Brake pad clips
Brake pad pin
Brake pad spring
Brake pads
Brake pad shims
Bleed screw
Refer to “REPLACING THE FRONT
BRAKE PADS”.
For installation, reverse the removal
procedure.
7-14
FRONT AND REAR BRAKES
CHAS
EAS00578
REAR BRAKE PADS
6 Nm (0.6 mkg)
27 Nm (2.7 mkg)
40 Nm (4.0 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the rear brake pads
Brake caliper bolts
Brake pads
Brake pad shims
Bleed screw
2
2
4
1
Refer to “REPLACING THE REAR
BRAKE PADS”.
For installation, reverse the removal
procedure.
7-15
FRONT AND REAR BRAKES
CHAS
EAS00579
CAUTION:
Disc brake components rarely require disassembly.
Therefore, always follow these preventive
measures:
Never disassemble brake components unless absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
Never use solvents on internal brake components.
Use only clean or new brake fluid for cleaning brake components.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
First aid for brake fluid entering the eyes:
Flush with water for 15 minutes and get immediate medical attention.
EAS00582
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake
calipers.
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Remove:
brake hose holder bolt 1
brake caliper 2
7-16
FRONT AND REAR BRAKES
CHAS
2. Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3
brake pads
(along with the brake pad shims)
3. Measure:
brake pad wear limit a
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm
4. Install:
brake pad shims
(onto the brake pads)
brake pads
brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2 . Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 mkg)
d. Install a new brake pad shim onto each new
brake pads.
e. Install new brake pads and a new brake pad
spring.
NOTE:
The arrow a on the brake pad spring must
point in the direction of disc rotation.
7-17
FRONT AND REAR BRAKES
5. Install:
brake pad pins
brake pad clips
brake caliper bolts
brake hose holder bolt
CHAS
40 Nm (4.0 mkg)
6 Nm (0.6 mkg)
6. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00583
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Remove:
brake caliper 1
2. Remove:
brake pads
(along with the brake pad shims)
7-18
FRONT AND REAR BRAKES
CHAS
3. Measure:
brake pad wear limit a
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
0.8 mm
4. Install:
brake pad shims
(onto the brake pads)
brake pads
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2 . Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 mkg)
d. Install a new brake pa shim onto each new
brake pad.
7-19
FRONT AND REAR BRAKES
5. Install:
brake caliper bolts
CHAS
40 Nm (4.0 mkg)
6. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7-20
CHAS
FRONT AND REAR BRAKES
EAS00584
FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR
6
30 Nm (3.0 mkg)
8
2
7
12
3
13
14
13
4
1
5
9
14
13
New
16
10
15
11
17
13 Nm (1.3 mkg)
Order
Job/Part
Q’ty
1
2
34
5
6
7
8
9
10
11
12
13
Removing the front brake master
cylinder and brake fluid reservoir
Brake fluidBrake fluid reservoir
cap stopper
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir
Brake fluid reservoir hose
Circlip
Dust cover
Hose joint
Brake lever
Front brake switch connector
Union bolt
Copper washer
7-21
Remarks
Remove the parts in the order listed.
Drain.
1
1
11
1
1
1
1
1
1
2
1
3
Disconnect.
Refer to “INSTALLING THE FRONT
BRAKE MASTER CYLINDER”.
CHAS
FRONT AND REAR BRAKES
6
30 Nm (3.0 mkg)
8
2
7
12
3
13
14
13
4
1
5
9
14
13
New
16
10
15
11
17
13 Nm (1.3 mkg)
Order
14
15
16
17
Job/Part
Q’ty
Brake hose
Brake master cylinder holder
Brake master cylinder
Front brake switch
2
1
1
1
Remarks
Refer to “INSTALLING THE FRONT
BRAKE MASTER SYLINDER”.
For installation, reverse the removal
procedure.
7-22
FRONT AND REAR BRAKES
CHAS
EAS00585
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Disassembling the front brake
master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder
1
1
1
1
For assembly, reverse the disassembly
procedure.
7-23
FRONT AND REAR BRAKES
CHAS
EAS00586
REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR
5 Nm (0.5 mkg)
30 Nm (3.0mkg)
23 Nm (2.3 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
Removing the rear brake master
cylinder and brake fluid reservoir
Brake fluid
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir
Brake fluid reservoir hose
Hose joint
Union bolt
Copper washer
Brake hose
Brake master cylinder
Remarks
Remove the parts in the order listed.
Drain.
1
1
1
1
1
1
1
2
1
1
Refer to “INSTALLING THE REAR
BRAKE MASTER SYLINDER”.
For installation, reverse the removal
procedure.
7-24
FRONT AND REAR BRAKES
CHAS
EAS00587
16 Nm (1.6 mkg)
Order
1
2
Job/Part
Q’ty
Disassembling the rear brake
master cylinder
Brake master cylinder kit
Brake master cylinder
Remarks
Remove the parts in the order listed.
1
1
For assembly, reverse the disassembly
procedure.
7-25
FRONT AND REAR BRAKES
CHAS
EAS00588
REMOVING THE FRONT BRAKE MASTER
CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Remove:
union bolt 1
copper washers 2
brake hoses 3
master cylinder holder 4
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
EAS00589
REMOVING THE REAR BRAKE MASTER
CYLINDER
1. Remove:
union bolt 1
copper washers 2
brake hose 3
button head bolts 4
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
A
EAS00593
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to both of the
brake master cylinders.
1. Check:
brake master cylinder
Damage/scratches/wear Replace.
brake fluid delivery passages
(brake master cylinder body)
Obstruction Blow out with compressed air.
A Front
B Rear
B
7-26
FRONT AND REAR BRAKES
CHAS
2. Check:
brake master cylinder kit
Damage/scratches/wear Replace.
Front
A
B Rear
A
B
A
3. Check:
brake fluid reservoir 1
Cracks/damage Replace.
brake fluid reservoir diaphragm 2
Cracks/damage Replace.
4. Check:
brake hoses
Cracks/damage/wear Replace.
B
EAS00607
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components.
Recommended brake fluid
DOT 4
7-27
FRONT AND REAR BRAKES
CHAS
1. Install:
brake master cylinder 1
13 Nm (1.3 mkg)
brake master cylinder holder
NOTE:
Install the brake master cylinder holder with
the “UP” mark facing up.
Align the end of the brake master cylinder
holder with the punch mark a in the right handlebar.
First, tighten the upper bolt, then the lower
bolt.
2. Install:
copper washers New
brake hose
union bolt
30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
NOTE:
While holding the brake hose, tighten the
union bolt as shown.
Turn the handlebars to the left and to the right
to make sure that the brake hose does not
touch other parts (e.g., wire harness, cables,
leads). Correct if necessary.
3. Fill:
brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
7-28
FRONT AND REAR BRAKES
CHAS
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00608
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
copper washers New
brake hoses
union bolt
30 Nm (3.0 mkg)
button head bolts
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure that the
brake pipe touches the projection a as
shown.
7-29
FRONT AND REAR BRAKES
CHAS
2. Fill:
brake fluid reservoir
Recommended brake fluid
DOT 4
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the reservoir. Water will significantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
5. Adjust:
brake pedal position
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
Brake pedal position (from the
top of the brake pedal to the bottom of the rider footrest bracket
bolt center)
4.3 9.3 mm
6. Adjust:
rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
7-30
FRONT AND REAR BRAKES
CHAS
EAS00613
FRONT BRAKE CALIPERS
6 Nm (0.6 mkg)
40 Nm (4.0 mkg)
30 Nm (3.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Drain.
Removing the front brake calipers
1
2
3
4
Remarks
Brake fluidUnion bolt
Union bolt
Copper washer
Brake hose
Brake caliper
1
2
1
1
Refer to “INSTALLING THE FRONT
BRAKE CALIPERS”.
For installation, reverse the removal
procedure.
7-31
FRONT AND REAR BRAKES
CHAS
EAS00615
6 Nm (0.6 mkg)
Order
Job/Part
Q’ty
Remarks
Disassemble the parts in the order listed.
Disassembling the front brake
calipers
The following procedure applies to both
of the front brake calipers.
1
2
3
4
5
6
7
2
1
1
2
4
8
1
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake caliper piston
Brake caliper piston seal
Bleed screw
Refer to “REMOVING THE FRONT
BRAKE CALIPERS”.
For assembly, reverse the disassembly
procedure.
7-32
FRONT AND REAR BRAKES
CHAS
EAS00616
REAR BRAKE CALIPER
30 Nm (3.0 mkg)
27 Nm (2.7 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper
1
2
1
1
Refer to “INSTALLING THE REAR
BRAKE CALIPERS”.
For installation, reverse the removal
procedure.
7-33
FRONT AND REAR BRAKES
CHAS
EAS00617
6 Nm (0.6 mkg)
Order
Job/Part
Q’ty
1
2
3
4
Disassembling the rear brake caliper
Brake pad
Brake caliper piston
Brake caliper piston seal
Bleed screw
2
2
4
1
Remarks
Disassemble the parts in the order listed.
Refer to “REMOVING THE REAR
BRAKE CALIPERS”.
For assembly, reverse the disassembly
procedure.
7-34
FRONT AND REAR BRAKES
CHAS
EAS00625
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
NOTE:
Before removing either brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
union bolt 1
copper washers 2
brake hose 3
brake caliper 4
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
a. Secure the right side brake caliper pistons
with a piece of wood a .
b. Blow compressed air into the brake hose
joint opening b to force out the pistons from
the brake caliper.
WARNING
Never try to pry out the brake caliper pistons.
Do not loosen the bolts 3 .
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
7-35
FRONT AND REAR BRAKES
CHAS
EAS00628
REMOVING THE REAR BRAKE CALIPER
NOTE:
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
a. Blow compressed air into the brake hose
joint opening a to force out the pistons from
the brake caliper.
Be careful not to get injured when the pistons
are expelled from the brake caliper..
WARNING
Cover the brake caliper piston with a rag.
Never try to pry out the brake caliper pistons.
b. Remove the brake caliper piston seals.
7-36
FRONT AND REAR BRAKES
CHAS
EAS00633
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule
A
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every four years
Brake fluid
Every two years and
whenever the brake
is disassembled
1. Check:
brake caliper pistons 1
Rust/scratches/wear Replace the brake
caliper.
brake caliper cylinders 2
Scratches/wear Replace the brake caliper.
brake calipers 3
Cracks/damage Replace.
brake fluid delivery passages
(brake caliper body)
Obstruction Blow out with compressed air.
B
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
A Front
B Rear
2. Check:
rear brake caliper bracket 1
Cracks/damage Replace.
7-37
FRONT AND REAR BRAKES
CHAS
EAS00640
INSTALLING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
brake caliper 1
(temporarily)
copper washers New
brake hose 2
union bolt 3
30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake caliper 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
2. Remove:
brake caliper
3. Install:
brake pads
brake pad spring
40 Nm (4.0 mkg)
brake caliper
brake hose holder
7 Nm (0.7 mkg)
Refer to “REPLACING THE FRONT BRAKE
PADS”.
7-38
FRONT AND REAR BRAKES
CHAS
4. Fill:
brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check;
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7-39
FRONT AND REAR BRAKES
CHAS
EAS00642
INSTALLING THE REAR BRAKE CALIPER
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
brake pads
brake caliper 1
copper washers New
brake hose 2
union bolt 3
30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake caliper 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
7-40
FRONT AND REAR BRAKES
CHAS
2. Fill:
brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
5. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7-41
FRONT FORK
CHAS
FRONT FORK
EAS00647
13 Nm (2.3 mkg)
23 Nm (2.3 mkg)
23 Nm (2.3 mkg)
23 Nm (2.3 mkg)
6 Nm (0.6mkg)
6 Nm (0.6mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to ”FRONT WHEEL AND BRAKE
DISCS”.
Refer to ”COWLINGS” in chapter 3.
Removing the front fork legs
Front brake calipers
Front wheel
1
2
3
4
5
6
7
8
9
Remarks
Front cowling inner panel
Front fender
Handlebar pinch bolt
Upper bracket bolt
Handlebar (left)
Handlebar (right)
Upper bracket pinch bolts
Cap bolts
Lower bracket pinch bolts
Front fork legs
1
2
2
1
1
2
2
4
2
Loosen
Loosen
Loosen
Loosen
For installation, reverse the removal
procedure.
7-42
FRONT FORK
CHAS
EB703002
23 Nm (2.3 mkg)
40 Nm (4.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
The following procedure applies to both of
the front fork legs.
Disassembling the front fork legs
1
2
3
4
5
6
7
8
9
10
Remarks
1
1
1
1
1
1
1
1
1
1
Cap bolt
O-ring
Nut
Washer
Spacer
Washer
Fork spring
Copper washer
Damper rod assembly bolt
Damper rod assembly
7-43
Refer to “DISASSEMBLING/
ASSEMBLING THE FRONT FORK
LEGS”.
FRONT FORK
CHAS
23 Nm (2.3 mkg)
40 Nm (4.0 mkg)
Order
11
12
13
14
15
16
17
Job/Part
Q’ty
1
1
1
1
1
1
1
Dust seal
Oil seal clip
Oil seal
Washer
Outer tube bushing
Inner tube
Oil lock piece
Remarks
Refer to “DISASSEMBLING/
ASSEMBLING THE FRONT FORK
LEGS”.
For assembly, reverse the disassembly
procedure.
7-44
FRONT FORK
CHAS
EAS00649
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Loosen:
upper bracket pinch bolt 3
cap bolt 2
handlebar pinch bolt 1
lower bracket pinch bolt
upper bracket bolt 4
handlebar 5
WARNING
Before loosening the upper and lower
bracket pinch bolts and handlebar pinch
bolt, support the front fork leg.
3. Remove:
front fork leg
EAS00655
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
cap bolt 1
(from the damper adjusting rod)
spacer 2
nut 3
a. Press down on the spacer with the fork
spring compressor 4 .
b. Install the rod holder 5 between the nut 3
and the spacer 2 .
Fork spring compressor
90890-01441
Rod holder
90890-01434
7-45
FRONT FORK
CHAS
NOTE:
Use the side of the rod holder that is marked “B”.
c. Loosen the nut.
d. Remove the cap bolt.
e. Remove the rod holder and fork spring compressor.
WARNING
The fork spring is compressed.
f. Remove the spacer and nut.
g. Remove the fork spring.
2. Drain:
fork oil
NOTE:
Stroke the damper rod 1 several times while
draining the fork oil.
3. Remove:
dust seal
oil seal clip 1
oil seal
washer
(with a flat-head screwdriver)
Slide metal
4. Remove:
damper rod assembly bolt
copper washer
NOTE:
While holding the damper rod with the damper
rod holder 1 , loosen the damper rod assembly
bolt.
Damper rod holder
90890-01425
7-46
FRONT FORK
CHAS
EAS00657
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
inner tube 1
outer tube 2
Bends/damage/scratches Replace.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
spring free length a
Out of specification Replace.
Spring free length limit
251.8 mm
<Limit>: 246 mm
3. Check:
damper rod 1
Damage/wear Replace.
Obstruction Blow out all of the oil passages with compressed air.
CAUTION:
The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly
sensitive to foreign material.
When disassembling and assembling the
front fork leg, do not allow any foreign material to enter the front fork.
7-47
FRONT FORK
CHAS
4. Check:
cap bolt O-ring
Damage/wear Replace.
EAS00661
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
Make sure that the oil levels in both front
fork legs are equal.
Uneven oil levels can result in poor handling and a loss of stability.
NOTE:
When assembling the front fork leg, be sure to
replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
Before assembling the front fork leg, make
sure that all of the components are clean.
1. Install:
oil lock piece
inner tube 2
damper rod assembly 1
WARNING
Always use new copper washers.
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube 2 until it protrudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Lubricate:
inner tube’s outer surface
Recommended lubricant
Yamaha fork and suspension oil
01 or equivalent
7-48
FRONT FORK
CHAS
3. Tighten:
damper rod assembly bolt 1
40 Nm (4.0 mkg)
NOTE:
While holding the damper rod with the damper
rod holder 2 , tighten the damper rod assembly
bolt.
Damper rod holder
90890-01425
4. Install:
outer tube bushing 1
washer 2
oil seal 3
oil seal clip 4
dust seal 5
CAUTION:
Make sure that the numbered side of the oil
seal faces up.
NOTE:
Before installing the oil seal, lubricate its lips
with lithium soap base grease.
Lubricate the outer surface of the inner tube
with fork oil.
Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 6 to protect
the oil seal during installation.
5. Install:
washer
oil seal 1
(with the fork seal driver 2 )
Fork seal driver weight
90890-01367
Fork seal driver attachment
90890-01374
6. Install:
oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
7-49
FRONT FORK
CHAS
7. Install:
dust seal 1
(with the fork seal driver 2 )
8. Install:
rod puller 1
adapter 2
(onto the damper rod 3 )
Rod puller
90890-01437
Adapter
90890-01436
9. Fully compress the front fork leg.
10. Fill:
front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
476 cm3
Recommended oil
Yamaha fork and suspension
oil 01
or equivalent
CAUTION:
Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
When disassembling and assembling the
front fork leg, do not allow any foreign material to enter the front fork.
11. After filling the front fork leg, slowly stroke
the damper rod 1 up and down (at least ten
times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod slowly because the fork oil may spurt out.
7-50
FRONT FORK
CHAS
12. Slowly stroke the inner tube 1 up and down
to distribute the fork oil once more (1 stroke
= about 100 mm).
NOTE:
Be careful not to stroke the inner tube over 100
mm as this will cause air to enter. If the inner
tube is stroked more than 100 mm, repeat steps
(12) and (13).
13. Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual
air.
14. Measure:
front fork leg oil level a
Out of specification Correct.
Front fork leg oil level (from the
top of the inner tube, with the
inner tube fully compressed,
and without the spring)
107 mm
15. Install:
nut 1
fork spring 2
washer 3
spacer 4
washer 5
damper adjusting rod 6
cap bolt 7
a. Remove the rod puller and adapter.
b. Install the nut.
7-51
FRONT FORK
CHAS
c. Install the rod puller and adapter onto the
damper rod.
Rod puller
90890-01437
Adapter
90890-01436
d. Install the fork spring, washers and spacer.
e. Press down on the spacer with the fork
spring compressor 8 .
f. Pull up the rod puller and install the rod holder 9 between the nut 1 and the spacer 4 .
NOTE:
Use the side of the rod holder that is marked “B”.
Fork spring compressor
90890-01441
Rod holder
90890-01434
g. Remove the rod puller and adapter.
h. Install the nut 1 and position it as specified
b.
Distance b
11 mm
i. Install the damper adjusting rod and cap bolt,
and then finger tighten the cap bolt.
j. Hold the cap bolt and tighten the nut to specification.
Nut:
15 Nm (1.5 mkg)
k. Remove the rod holder and fork spring compressor.
WARNING
The fork spring is compressed.
Always use a new cap bolt O-ring.
7-52
FRONT FORK
CHAS
16. Install:
cap bolt
(onto the inner tube)
NOTE:
Temporarily tighten the cap bolt.
EAS00662
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
NOTE:
Make sure that the inner fork tube is flush with
the top of the handlebar.
2. Tighten:
lower bracket pinch bolt
23 Nm (2.3 mkg)
handlebar pinch bolt 1
33 Nm (3.3 mkg)
23 Nm (2.3 mkg)
cap bolt 2
3
upper bracket pinch bolt
26 Nm (2.6 mkg)
WARNING
Make sure that the brake hoses are routed
properly.
3. Adjust:
spring preload
rebound damping
compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.
7-53
HANDLEBARS
CHAS
EAS00665
HANDLEBARS
115 Nm (11.5 mkg)
13 Nm (1.3 mkg)
13 Nm (1.3 mkg)
13 Nm (1.3 mkg)
18
13 Nm (1.3 mkg)
23 Nm (2.3 mkg)
Order
Job/Part
Q’ty
1
2
3
4
Removing the handlebars
Left grip end
Handlebar grip
Clutch switch connector
Left handlebar switch
1
1
2
1
5
6
7
8
9
10
11
Starter cable
Starter lever
Clutch cable
Clutch lever holder
Right grip end
Throttle cable
Throttle grip
1
1
1
1
1
2
1
7-54
Remarks
Remove the parts in the order listed.
Refer to “REMOVING/INSTALLING THE
HANDLEBARS”.
Disconnect.
Refer to “INSTALLING THE
HANDLEBARS”.
Disconnect.
Disconnect.
Refer to “INSTALLING THE
HANDLEBARS”.
HANDLEBARS
CHAS
115 Nm (11.5 mkg)
13 Nm (1.3 mkg)
13 Nm (1.3 mkg)
13 Nm (1.3 mkg)
18
13 Nm (1.3 mkg)
23 Nm (2.3 mkg)
Order
12
13
14
15
16
17
18
19
20
21
22
Job/Part
Q’ty
2
1
1
1
2
2
2
1
1
1
1
Front brake switch connector
Right handlebar switch
Brake master cylinder holder
Brake master cylinder
Handlebar pinch bolt
Upper bracket bolt
Upper bracket pinch bolt
Steering stem nut
Left handlebar
Right handlebar
Upper bracket
Remarks
Disconnect.
Refer tp “INSTALLING THE
HANDLEBARS”.
For installation, reverse the removal
procedure.
7-55
HANDLEBARS
CHAS
EAS00667
REMOVING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
grip end
handlebar grip
left handlebar switch
clutch lever holder
NOTE:
Blow compressed air between the left handlebar and the handlebar grip, and gradually push
the grip off the handlebar.
3. Remove:
grip end
right handle switch 1
throttle grip 2
right handlebar switch
brake master cylinder holder
EAS00669
CHECKING THE HANDLEBARS
1. Check:
left handlebar
right handlebar
Bends/cracks/damage Replace.
WARNING
Do not attempt to straighten bent handlebars as this may dangerously weaken them.
7-56
HANDLEBARS
CHAS
EAS00674
INSTALLING THE HANDLEBARS
1. Install:
brake master cylinder holder 1
CAUTION:
Install the brake master cylinder holder
with the “UP” mark facing up.
First, tighten the upper bolt, then the lower
bolt.
NOTE:
Align the mating surfaces of the brake master
cylinder holder with the punch mark a in the
right handlebar.
There should be 2 mm of clearance between
the right handlebar switch and the brake master cylinder holder.
2. Install:
right handlebar switch 1
throttle cables
grip end
NOTE:
Align the projection a on the throttle cable
housing with the hole b in the right handlebar.
3. Install:
clutch lever holder 1
NOTE:
Align the slit in the clutch lever holder with the
punch mark a in the left handlebar.
7-57
HANDLEBARS
CHAS
4. Install:
left handlebar switch 1
NOTE:
Align the projection a on the left handlebar
switch with the hole b in the left handlebar.
5. Install:
handlebar grip
grip end
a. Apply a thin coat of rubber adhesive onto the
end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
6. Adjust:
clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
Clutch cable free play (at the end
of the clutch lever)
10 15 mm
7. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
6 8 mm
7-58
STEERING HEAD
CHAS
EAS00676
STEERING HEAD
LOWER BRACKET
13 Nm (1.3 mkg)
115 Nm (11.5 mkg)
13 Nm (1.3 mkg)
23 Nm (2.3 mkg)
23 Nm (2.3 mkg)
1st. 17 Nm (1.7 mkg)
2nd. 9 Nm (0.9 mkg)
Order
Job/Part
Q’ty
Removing the lower bracket
Front wheel
1
2
3
4
5
6
7
8
9
10
11
12
Front fork legs
Main switch coupler
Upper bracket bolt
Left handlebar assembly
Right handlebar assembly
Steering stem nut
Washer
Upper bracket
Lower bracket panel
Brake hose holder bolt
Lock washer
Upper ring nut
Rubber washer
2
2
1
1
1
1
1
1
2
1
1
1
7-59
Remarks
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “FRONT FORK”.
Disconnect.
Refer to ”CHECK AND ADJUSTING THE
STEERING HEAD” in chapter 3.
STEERING HEAD
13 Nm (1.3 mkg)
CHAS
115 Nm (11.5 mkg)
13 Nm (1.3 mkg)
23 Nm (2.3 mkg)
23 Nm (2.3 mkg)
1st. 17 Nm (1.7 mkg)
2nd. 9 Nm (0.9 mkg)
Order
Job/Part
Q’ty
Remarks
Refer to “CHECK AND ADJUSTING THE
STEERING HEAD” in chapter 3.
13
Lower ring nut
1
14
15
16
17
18
19
20
Lower bracket
Bearing cover
Bearing inner race
Upper bearing
Lower bearing
Dust seal
Bearing outer race
1
1
2
1
1
1
2
For installation, reverse the removal
procedure.
7-60
STEERING HEAD
CHAS
EAS00677
REMOVING THE LOWER BRACKET
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
front fork legs
steering stem nut
upper bracket
ring nuts 1
(with the special tool 2 )
Ring nut wrench
90890-01403
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS00682
CHECKING THE STEERING HEAD
1. Wash:
bearing balls
bearing races
Recommended cleaning solvent
Kerosine
2. Check:
bearing balls 1
bearing races 2
Damage/pitting Replace.
3. Replace:
bearing balls
bearing races
a. Remove the bearing races from the steering
head pipe with a long rod 1 and hammer.
7-61
STEERING HEAD
CHAS
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install a new dust seal and new bearing
races.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the bearing balls and bearing
races as a set.
Whenever the steering head is disassembled,
replace the dust seal.
4. Check:
upper bracket
lower bracket
(along with the steering stem)
Bends/cracks/damage Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:
upper bearing
lower bearing
bearing races
Recommended lubricant
Lithium soap base grease
2. Install:
bearing
bearing cover
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
7-62
STEERING HEAD
CHAS
3. Install:
upper bracket
steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
4. Install:
front fork legs
Refer to “FRONT FORK”.
NOTE:
Temporarily tighten the upper and lower bracket
pinch bolts, and handlebar pinch bolts.
5. Tighten:
steering stem nut
lower bracket pinch bolt
115 Nm (11.5 mkg)
23 Nm (2.3 mkg)
upper bracket pinch bolt
upper bracket bolt
handlebar pinch bolt
7-63
23 Nm (2.3 mkg)
13 Nm (1.3 mkg)
13 Nm (1.3 mkg)
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
40 Nm (4.0 mkg)
40 Nm (4.0 mkg)
40 Nm (4.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the rear shock absorber
assembly
Rear wheel
Self-locking nut/bolt
Self-locking nut/bolt
Self-locking nut/bolt/coller
Self-locking nut/bolt
Pin/clip/washer
Rear shock absorber assembly
Coller/oil seal/bearing
Relay arm
Coller/oil seal/bearing
Connecting arm
Coller/oil seal/bearing
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “REMOVING THE REAR WHEEL”.
1/1
1/1
1/1/1 Refer to “REMOVING THE REAR
1/1 SHOCK ABSORBER ASSEMBLY”.
1/1/1
1
1/2/1
2
1/2/1
1
1/2/1
For installation, reverse the removal
procedure.
7-64
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00687
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
WARNING
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you understand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.
Do not tamper or attempt to open the rear
shock absorber or gas cylinder.
Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause
an explosion due to excessive gas pressure.
Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EAS00689
DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER
Gas pressure must be released before disposing of a rear shock absorber and gas cylinder.
To release the gas pressure, press on the gas
valve needle with a suitable tool as shown, until
all of the gas is released (the hissing has
stopped).
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
7-65
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00694
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
rear wheel
rear shock absorber assembly lower bolt 1
relay-arm-to-swingarm bolt 2
NOTE:
While removing the rear shock absorber assembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:
rear shock absorber assembly upper bin 1
rear shock absorber assembly
NOTE:
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm.
EAS00696
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY AND GAS CYLINDER
1. Check:
rear shock absorber rod
Bends/damage Replace the rear shock
absorber assembly.
rear shock absorber
Gas leaks/oil leaks Replace the rear
shock absorber assembly.
spring
Damage/wear Replace the rear shock
absorber assembly.
gas cylinder
Damage/gas leaks Replace.
bushings
Damage/wear Replace.
dust seals
Damage/wear Replace.
bolts
Bends/damage/wear Replace.
7-66
REAR SHOCK ABSORBER ASSEMBLY
CHAS
CHECKING THE RELAY ARM AND CONNECTING ARM
1. Check:
relay arm 1
connecting arm 2
Damage/wear Replace.
bearings
oil seals
Damage/pitting Replace.
spacers
Damage/scratches Replace.
EAS00698
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY
1. Lubricate:
bearings
oil seals
spacers
Recommended lubricant
Lithium soap base grease
2. Install:
connecting arm
relay arm
rear shock absorber assembly
NOTE:
When installing the rear shock absorber assembly, lift up the swingarm.
3. Tighten:
connecting-arm-to-frame nut
40 Nm (4.0 mkg)
relay-arm-to-connecting-arm nut
40 Nm (4.0 mkg)
relay-arm-to-swingarm nut
40 Nm (4.0 mkg)
rear shock absorber assembly lower nut
40 Nm (4.0 mkg)
7-67
SWINGARM AND DRIVE CHAIN
CHAS
EAS00700
SWINGARM AND DRIVE CHAIN
95 Nm (9.5 mkg)
6 Nm (0.6 mkg)
6 Nm (0.6 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the swingarm and drive
chain
Drive sprocket
Rear wheel
Refer to “ENGINE” in chapter 4.
Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Rear shock absorber assembly
1
2
3
4
5
6
7
Adjusting bolt/locknut
Drive chain guard
Rear fender
Flap
Pivot shaft nut/washer
Pivot shaft
Swingarm
Remarks
2/2
1
1
1
1/1
1
1
7-68
SWINGARM AND DRIVE CHAIN
CHAS
95 Nm (9.5 mkg)
6 Nm (0.6 mkg)
6 Nm (0.6 mkg)
Order
Job/Part
Q’ty
Remarks
Refer to “REMOVING/INSTALLING THE
SWINGARM”.
8
Pivot shaft adjust bolt
2
9
10
11
12
13
14
15
16
17
Drive chain
Dust cover
Oil seal
Bush
Shim
Drive chain guide
Bush
Left bearing
Right bearing
1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
7-69
SWINGARM AND DRIVE CHAIN
CHAS
NOTE:
Before removing the drive sprocket, drive chain,
and rear wheel, measure the drive chain slack
and the length of a tenlink section of the drive
chain.
EC573000
REMOVING THE SWINGARM
1. Remove:
Bolt (connecting rod) 1
Connecting rod 2
NOTE:
Remove the bolt while holding the swingarm.
2. Loosen:
Pivot shaft adjust bolt 1
NOTE:
Loosen the pivot shaft adjust bolt using a pivot
shaft wrench 2
Pivot shaft wrench:
90890-01471
3. Remove:
Pivot shaft 1
Swingarm
EAS00704
REMOVING THE DRIVE CHAIN
1. Remove:
drive chain
NOTE:
Only cut the drive chain if or the swingarm is to
be replaced.
7-70
SWINGARM AND DRIVE CHAIN
CHAS
EAS00703
CHECKING THE SWINGARM
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Measure:
swingarm side play
swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
95 Nm (9.5mkg)
b. Measure the swingarm side play A by moving the swingarm from side to side.
c. If the swingarm side play is out of specification, check the spacers, bearings, washers,
and dust covers.
Swingarm side play (at the end
of the swingarm)
1.0mm
d. Check the swingarm vertical movement B
by moving the swingarm up and down.
If swingarm vertical movement is not smooth or
if there is binding, check the spacers, bearings,
washers, and bust covers.
3. Check:
swingarm
Bends/cracks/damage Replace.
NOTE:
If the swingarm must be replaced, the drive
chain must be cut with a drive chain cutter.
7-71
SWINGARM AND DRIVE CHAIN
CHAS
4. Check:
pivot shaft
Roll the pivot shaft on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
5. Wash:
pivot shaft
pivot shaft adjust bolt
dust covers
spacer
bearings
Recommended cleaning solvent
Kerosine
6. Check:
dust covers
spacer
oil seals
Damage/wear Replace.
bearings
Damage/pitting Replace.
7-72
SWINGARM AND DRIVE CHAIN
CHAS
EAS00709
CHECKING THE DRIVE CHAIN
1. Measure:
ten-link section a of the drive chain
Out of specification Replace the drive
chain.
Max. ten-link drive chain section
149 mm
NOTE:
While measuring the ten-link section, push
down on the drive chain to increase its tension.
Measure the length between drive chain roller
1 and 11 as shown.
Perform this measurement at two or three different places.
2. Check:
drive chain
Stiffness Clean and lubricate or replace.
3. Clean:
drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosine and remove
any remaining dirt.
7-73
SWINGARM AND DRIVE CHAIN
CHAS
c. Remove the drive chain from the kerosine
and completely dry it.
CAUTION:
This motorcycle has a drive chain with small
rubber O-rings 1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean
the drive chain.
High-pressure methods could force dirt or
water into the drive chain’s internals, and
solvents will deteriorate the O-rings. A
coarse brush can also damage the O-rings.
Therefore, use only kerosine to clean the
drive chain.
Don’t soak drive drain in kerosine more
them ten minutes. O-ring is damage by kerosine.
4. Check:
O-rings 1
Damage Replace the drive chain.
drive chain rollers 2
Damage/wear Replace the drive chain.
drive chain side plates 3
Cracks/damage/wear Replace the drive
chain.
5. Lubricate:
drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
6 Check:
drive sprocket
rear wheel sprocket
More than 1/4 tooth a wear Replace the
drive chain sprockets as a set.
Bent teeth Replace the drive chain
sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
7-74
SWINGARM AND DRIVE CHAIN
CHAS
EAS00711
INSTALLING THE SWINGARM
1. Lubricate:
bearings
spacers
dust covers
pivot shaft
Recommended lubricant
Lithium soap base grease
2. Install:
swingarm
pivot shaft
washer
pivot shaft adjust bolt 1
pivot shaft nut
95 Nm (9.5 mkg)
NOTE:
Use the pivot shaft wrench 2 to tighten the pivot adjust bolt to finger tightness.
Pivot shaft wrench:
90890-1471
3. Install:
rear shock absorber assembly
rear wheel
Refer to “REAR SHOCK ABSORBER ASSEMBLY” and “REAR WHEEL”.
4. Adjust:
drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack
40 50 mm
EAS00713
INSTALLING THE DRIVE CHAIN
1. Lubricate:
drive chain
2. Install:
drive chain
(with the drive chain riveter)
7-75
CHAS
–
ELEC
+
8
ELEC
CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
INSTRUMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT . . . . . .
COMBINATION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2
8-2
8-2
8-3
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . .
TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . .
CHECKING THE LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8
8-8
8-8
8-10
8-10
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT CUTOFF SYSTEM OPERATION . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-16
8-16
8-17
8-18
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 8-25
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
8-29
8-29
8-30
8-31
ELEC
SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
8-35
8-35
8-37
8-38
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-49
8-49
8-50
8-51
8-53
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
ELECTRICAL COMPONENTS
ELEC
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
9
Wire harness
Main switch
Front brake light switch
Plug top ignition coils
Clutch switch
Starting circuit cutoff relay
Fuse box
Flasher relay
CDI unit
10
11
12
13
14
15
16
17
18
19
Starter relay
Main fuse
Oil level relay
Battery
Rectifier/ regulator
Rear brake light switch
Neutral switch
Speed sensor
Sidestand switch
Stator coil assembly
8-1
20
21
22
23
24
25
26
Oil level switch
Pickup coil
Radiator fan
Horn
Thermo unit
Thermo switch
Headlight relay (HI, LO)
INSTRUMENT FUNCTIONS
ELEC
INSTRUMENT FUNCTIONS
INDICATOR LIGHTS
1 Neutral indicator light “
”
2 High beam indicator light “
3 Turn indicator light “
4 Fuel indicator light “
Turn indicator light “ ”
This indicator flashes when the turn switch is
moved to the left or right.
Neutral indicator light “ ”
This indicator comes on when the transmission is in neutral.
High beam indicator light “
”
This indicator comes on when the headlight
high beam is used.
Fuel indicator light “ ”
When the fuel level drops below approximately 3.7 L, this light will come on.
When this light comes on, fill the fuel tank at
the first opportunity.
”
”
”
OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT
1 Oil level / coolant temperature warning light “
”
3 Coolant temperature symbol “
This warning light has two functions.
The light will come on and symbol “
” will
flash if the engine oil level is low. If this symbol flashes, stop the engine immediately
and fill it with oil to the specified level.
The light will come on and symbol “ ” will
flash if the coolant temperature is too high.
The following chart shows the conditions of
the indicator light, symbol and temperature
display in accordance with the coolant temperature.
”
CAUTION:
2 Oil level symbol “
”
Do not run the motorcycle until you know it
has sufficient engine oil.
Do not run the motorcycle if the engine is
overheated.
NOTE:
Even if the oil is filled to the specified level, the
warning light may flicker when riding on a slope
or during sudden acceleration or deceleration,
but this is normal.
8-2
INSTRUMENT FUNCTIONS
Coolant
temperature
Display
Conditions
ELEC
What to do
0_C 40_C
Symbol is on and
“LO” is displayed.
Go ahead with riding.
41_C 117_C
Symbol is on and
temperature is displayed.
Go ahead with riding.
118_C 140_C
Symbol and temperature flashes
and indicator light
comes on.
Stop the motorcycle and
allow it to idle until the
coolant temperature goes
down.
If the temperature does
not go down, stop the engine. Refer to “OVERHEATING” in chapter 9.
141 _C Symbol flashes,
“HI” is displayed
and flashes, and
the indicator light
comes on.
Stop the engine and allow
it to cool.
Refer to “OVERHEATING”
in chapter 9.
COMBINATION METER
This combination meter is equipped with the following.
S A speedometer
S An odometer
S Two trip odometers
S A fuel reserve tripmeter
S A clock
For GB and USA models only:
To change the speedometer display from kilometers to miles, press the “SELECT” button for
at least two seconds.
1 Speedometer
2 Clock, odometer
Odometer and trip meters
Use the trip meters to estimate how far you can
ride on a tank of fuel.
Use the fuel reserve trip meter to see the distance traveled from when the fuel level dropped
to the reserve level.
3 “SELECT” button
4 “RESET” button
Push the “SELECT” button to change between
the odometer mode “ODO” and the trip odometer modes “TRIP 1”and “TRIP 2” in the following
order:
“ODO” “TRIP 1” “TRIP 2” “ODO”
8-3
INSTRUMENT FUNCTIONS
ELEC
When the fuel level indicator light comes on the
odometer display will automatically change to
the fuel reserve trip meter mode “TRIP F” and
start counting the distance traveled from that
point. Push the “SELECT” button to change between the fuel odometer, trip odometer and
odometer modes in the following order:
“TRIP F” “TRIP 1” “TRIP 2” “ODO” “TRIP F”
To reset a trip odometer to 0.0, select it by pushing the “SELECT” button and push the “RESET”
button for at least one second. To reset the fuel
reserve trip meter, select it by pushing the “SELECT” button and push the “RESET” button for
at least one second.
The display will return to “TRIP 1”. If you do not
reset the fuel reserve trip meter manually, it will
automatically reset and return to “TRIP 1” after
refueling and the motorcycle has traveled both
5 km and for approximately 3 minutes.
Clock
To change the display to the clock mode, push
both the “SELECT” and “RESET” buttons.
To set the clock:
1. Push both the “SELECT” and “RESET” buttons for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button to set the hours.
3. Push the “SELECT” button to change the
minutes.
4. When the minute digits start flashing, push
the “RESET” button to set the minutes.
5. Push the “SELECT” button to start the clock.
NOTE:
After setting the clock, be sure to push the “SELECT” button before turning the main switch to
“OFF”, otherwise the clock will not be set.
8-4
SWITCHES
ELEC
EB801000
SWITCHES
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect,
check the wiring connections and if necessary,
replace the switch.
CAUTION:
Never insert the tester probes into the coupler terminal slots 1 . Always insert the
probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω 1” range.
When checking for continuity, switch back and
forth between the switch positions a few times.
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far left
column and the switch lead colors b are shown
in the top row in the switch illustration.
NOTE:
“
” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows
that:
There is continuity between blue/red and red
when the switch is set to “ ”.
There is continuity between blue/red and blue,
between brown/blue and red, and between
blue/yellow and blue/black when the switch is
set to “ON”.
8-5
CHECKING THE SWITCHES
ELEC
EB801010
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear Repair or replace the switch.
Improperly connected Properly connect.
Incorrect continuity reading Replace the switch.
8-6
CHECKING THE SWITCHES
1
2
3
4
5
6
7
8
Main switch
Pass switch
Dimmer switch
Turn signal switch
Horn switch
Clutch switch
Light switch (for Europe)
Engine stop switch
Start switch
Front brake light switch
Rear brake light switch
Neutral switch
Fuse
Sidestand switch
Oil level switch
*: for AUS
9
10
11
12
13
14
15
8-7
ELEC
CHECKING THE BULBS AND BULB SOCKETS
ELEC
EB801020
CHECKING THE
BULB SOCKETS
BULBS
AND
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continuity between the terminals.
Damage/wear Repair or replace the bulb,
bulb socket or both.
Improperly connected Properly connect.
Incorrect continuity reading Repair or replace the bulb, bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.
Bulbs A and B are used for headlights and
usually use a bulb holder which must be detached before removing the bulb. The majority
of these bulbs can be removed from their respective socket by turning them counterclockwise.
Bulb C is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclockwise.
Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out.
CHECKING THE CONDITION OF THE BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
bulb
8-8
CHECKING THE BULBS AND BULB SOCKETS
ELEC
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
CAUTION:
Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in
the coupler.
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:
bulb (for continuity)
(with the pocket tester)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.
a. Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
3 , and check the continuity.
b. Connect the tester positive probe to terminal
2 and the tester negative probe to terminal
3 , and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
8-9
CHECKING THE BULBS AND BULB SOCKETS
ELEC
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
bulb socket (for continuity)
(with the pocket tester)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the respective leads of the bulb socket.
c. Check the bulb socket for continuity.
If any of the readings indicate no continuity,
replace the bulb socket.
CHECKING THE LEDs
The following procedure applies to all of the
LEDs.
1. Check:
LED (for proper operation)
a. Disconnect the meter assembly coupler
(meter assembly side).
b. Connect two jumper leads 1 from the battery terminals to the respective coupler terminals as shown.
WARNING
A wire that is used as a jumper lead must
have at least the same capacity of the battery lead, otherwise the jumper lead may
burn.
This check is likely to produce sparks,
therefore make sure that no flammable gas
or fluid is in the vicinity.
c. When the jumper leads are connected to the
terminals the respective LED should illuminate.
Does not light Replace the meter assembly.
8-10
IGNITION SYSTEM
ELEC
EB802001
IGNITION SYSTEM
CIRCUIT DIAGRAM
1
5
6
9
11
14
15
16
17
18
19
20
21
56
63
66
8-11
Main switch
Battery
Main fuse
Starting circuit cutoff relay
Sidestand switch
CDI unit
Ignition coil #1
Ignition coil #2
Ignition coil #3
Ignition coil #4
Spark plugs
Pick up coil
Neutral switch
Ignition fuse
Engine stop switch
Diode 2
IGNITION SYSTEM
EB802011
ELEC
EB802401
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. pickup coil resistance
8. main switch
9. engine stop switch
10. neutral switch
11. sidestand switch
12. starting circuit cutoff relay
13. wiring
(of the entire ignition system)
Min. open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) rider seat
2) fuel tank
3) air filter case
4) heat protector plate
5) front cowling inner panel (right)
6) side cowling inner panel (right)
7) side cowling (right)
S Troubleshoot with the following special tool
(-s).
EB802403
3. Spark plugs
The following procedure applies to all of the
spark plugs.
S Check the condition of the spark plug.
S Check the spark plug type.
S Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in chapter 3.
Standard spark plug
CR10EK (NGK)
Spark plug gap
0.6 0.7 mm
Ignition checker
90890-06754
Pocket tester
90890-03112
S Is the spark plug in good condition, is it of the
correct type, and its gap within specification?
YES
NO
EB802400
1. Main and ignition fuses
Re-gap or replace the
spark plug.
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main and ignition fuses OK?
YES
NO
Replace the fuse(-s).
8-12
ELEC
IGNITION SYSTEM
EB802405
EB802409
4. Ignition spark gap
6. Ignition coil resistance
The following procedure applies to all of the
spark plugs.
S Disconnect the spark plug cap from the spark
plug.
S Connect the ignition checker 1 as shown.
S 2 Spark plug cap
S Set the main switch to “ON”.
S Measure the ignition spark gap a .
S Crank the engine by pushing the start switch
and gradually increase the spark gap until a
misfire occurs.
The following procedure applies to all of the
ignition coils.
S Disconnect the ignition coil connectors from
the ignition coil terminals.
S Connect the pocket tester (Ω 1) to the ignition coil as shown.
Tester positive probe ignition coil terminal
Tester negative probe ignition coil terminal
S Measure the primary coil resistance.
Min. ignition spark gap
6 mm
Primary coil resistance
0.238 X 0.322 Ω at 20_C
S Is there a spark and is the spark gap within
specification?
NO
S Connect the pocket tester (Ω
1k) to the
ignition coil as shown.
S Measure the secondary coil resistance.
YES
Tester positive probe ignition coil terminal 1
Tester positive probe spark plug terminal 2
The ignition system is
OK.
Secondary coil resistance
8.16 X 11.04 kΩ at 20_C
S Is the ignition coil OK?
YES
NO
Replace the ignition
coil.
8-13
IGNITION SYSTEM
EB802410
ELEC
EB802411
7. Pickup coil resistance
8. Main switch
S Disconnect the pickup coil coupler from the
wire harness.
S Connect the pocket tester (Ω
100) to the
pickup coil terminal.
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES
Tester positive probe gray 1
Tester negative probe black 2
NO
Replace the main
switch.
EB802412
9. Engine stop switch
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
S Measure the pickup coil resistance.
YES
Pickup coil resistance
248 X 372 Ω at 20_C
(between gray and black)
NO
Replace the right
handlebar switch.
S Is the pickup coil OK?
YES
NO
EB802413
10. Neutral switch
Replace the pickup
coil.
S Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
EB802414
11. Sidestand switch
S Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the sidestand switch OK?
YES
NO
Replace the sidestand switch.
8-14
IGNITION SYSTEM
EB802415
ELEC
EB802416
12. Starting circuit cutoff relay
13. Wiring
Remove the relay unit from the wire harness.
Connect the pocket tester (Ω 1) to the relay
terminals as shown.
Check the starting circuit cutoff relay for continuity.
Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the ignition system’s wiring properly connected and without defects?
NO
Tester positive probe sky blue 1
Tester negative probe blue/yellow 2
No
continuity
Tester positive probe blue/yellow 2
Tester negative probe sky blue 1
Continuity
Properly connect or
repair the ignition
system’s wiring.
NOTE:
When you switch the “–” and “)” leads of the
digital pocket tester, the readings in the above
chart will be reversed.
Are the tester readings correct?
YES
NO
Replace the starting
circuit cutoff relay.
8-15
YES
Replace the ignitor
unit.
ELECTRIC STARTING SYSTEM
ELEC
EB803000
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
1
5
6
7
8
9
11
21
38
56
63
64
65
8-16
Main switch
Battery
Main fuse
Starter relay
Starter motor
Starting circuit cutoff relay
Sidestand switch
Neutral switch
Clutch switch
Ignition fuse
Engine stop switch
Start switch
Diode 1
ELECTRIC STARTING SYSTEM
ELEC
EB803010
STARTING CIRCUIT CUTOFF SYSTEM OPERATION
If the engine stop switch is set to “ ” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:
The transmission is in neutral (the neutral
switch is closed).
The clutch lever is pulled to the handlebar (the
clutch switch is closed) and the sidestand is up
(the sidestand switch is closed).
The starting circuit cutoff relay prevents the
starter motor from operating when neither of
these conditions has been met. In this instance,
the starting circuit cutoff relay is open so current
cannot reach the starter motor. When at least
one of the above conditions has been met the
starting circuit cutoff relay is closed and the engine can be started by pressing the start switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED TO
THE HANDLEBAR
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cutoff relay
7 Diode
8 Clutch switch
9 Sidestand switch
10 Neutral switch
11 Start switch
12 Starter relay
13 Starter motor
8-17
ELECTRIC STARTING SYSTEM
EB803020
ELEC
EB802401
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
The starter motor fails to turn.
Check:
1. main and ignition fuses
2. battery
3. starter motor
4. starting circuit cutoff relay
5. Diode
6. starter relay
7. main switch
8. engine stop switch
9. neutral switch
10. sidestand switch
11. clutch switch
12. start switch
13. wiring
(of the entire starting system)
Open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or
replace the battery.
NOTE:
S Before, troubleshooting, remove the following
part(-s):
1) rider seat
2) fuel tank
3) air filter case
4) front cowling inner panels
5) Side cowling inner panels
6) Side cowlings
S Troubleshoot with the following special tool
(-s).
EB803400
3. Starter motor
S Connect the battery positive terminal 1 and
starter motor lead 2 with a jumper lead 3 .
Pocket tester
90890-03112
EB802400
1. Main and ignition fuses
WARNING
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main and ignition fuses OK?
YES
S A wire that is used as a jumper lead must
have at least the same capacity of the
battery lead, otherwise the jumper lead
may burn.
S This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.
NO
S Does the starter motor turn?
Replace the fuse(-s).
YES
NO
Repair or replace the
starter motor.
8-18
ELECTRIC STARTING SYSTEM
EB803402
ELEC
EB803403
4. Starting circuit cutoff relay
5. DIODE
Disconnect the relay from the coupler.
Connect the pocket tester (Ω
1) and battery (12 V) to the relay terminals as shown.
Disconnect the relay from the coupler.
Connect the pocket tester (Ω 1) to the relay
terminals as shown.
Measure the starting circuit cutoff relay for
continuity as follows.
Battery positive terminal red/black 1
Battery negative terminal black/yellow 2
Tester positive probe sky blue 1
Tester negative probe black/yellow 2
Tester positive probe blue/white 3
Tester negative probe black 4
Tester positive probe sky blue 1
Tester negative probe blue/yellow 3
No
continuity
Tester positive probe black/yellow 2
Tester negative probe sky blue 1
Tester positive probe blue/yellow 3
Tester negative probe sky blue 1
Does the starting circuit cutoff relay have
continuity between black and blue/white?
YES
NO
Continuity
Replace the starting
circuit cutoff relay
NOTE:
When you switch the “–” and “)” leads of the
digital pocket tester, the readings in the above
chart will be reversed.
Are the tester readings correct?
YES
NO
Replace the starting
circuit cutoff relay
8-19
ELECTRIC STARTING SYSTEM
EB803404
ELEC
EB802412
6. Starter relay
8. Engine stop switch
Disconnect the starter relay from the coupler.
Connect the pocket tester (Ω
1) and battery (12 V) to the starter relay coupler as
shown.
Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the engine stop switch OK?
YES
Battery positive terminal red/white 1
Battery negative terminal blue/white 2
NO
Replace the right
handlebar switch.
Tester positive probe red 3
Tester negative probe black 4
EB802413
9. Neutral switch
Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the neutral switch OK?
YES
Replace the neutral
switch.
Does the starter relay have continuity between red and black?
YES
NO
NO
10. Diode
Replace the starter
relay.
Check the diode for continuty.
Disconnect the diode from the coupler.
Connect the pocket tester (Ω 1) to the diode
terminals as a shown.
Measur the diode for continuity as follows.
EB802411
7. Main switch
Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
YES
NO
Replace the main
switch.
Tester positive probe blue/yellow 1
Tester negative probe blue/black 2
No
continuity
Tester positive probe blue/black 2
Tester negative probe blue/yellow 1
Continuity
Is the diode ok?
YES
NO
Replace the diode.
8-20
ELECTRIC STARTING SYSTEM
EB8022414
11. Sidestand switch
Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the sidestand switch OK?
YES
NO
Replace the
sidestand switch.
EB803405
12. Clutch switch
Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the clutch switch OK?
YES
NO
Replace the clutch
switch.
EB803406
13. Start switch
Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
EB803408
14. Wiring
Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the starting system’s wiring properly connected and without defects?
NO
Properly connect or
repair the starting
system’s wiring.
YES
The starting system
circuit is OK.
8-21
ELEC
STARTER MOTOR
ELEC
EAS00767
STARTER MOTOR
5Nm (0.5mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “CARBURETORS” in chapter 6.
Drain
Refer to “CHANGING THE COOLANT”
in chapter 3.
Refer to “THERMOSTAT” in chapter 5.
Removing the starter motor
Rider seat
Fuel tank
Carburetors
Coolant
1
2
3
Remarks
Thermostat
Starter motor lead
Starter motor assembly
Throttle stop screw
1
1
1
For installation, reverse the removal
procedure.
8-22
STARTER MOTOR
ELEC
5Nm (0.5mkg)
10 Nm (1.0mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Disassembling the starter motor
O-ring
Starter motor front cover
Lock washer
Oil seal
Bearing
Washer set
Starter motor rear cover
Washer set
O-ring
Brush holder set
O-ring
Armature assembly
Starter motor yoke
1
1
1
1
1
1
1
1
2
1
1
1
1
For assembly, reverse the disassembly
procedure.
8-23
STARTER MOTOR
ELEC
EB803511
CHECKING THE STARTER MOTOR
1. Check:
S commutator
Dirt Clean with 600 grit sandpaper.
2. Measure:
S commutator diameter a
Out of specification Replace the starter
motor.
Min. commutator diameter
27 mm
3. Measure:
S mica undercut a
Out of specification Scrape the mica to the
proper measurement with a hacksaw blade
which has been grounded to fit the commutator.
Mica undercut
0.7 mm
NOTE:
The mica must be undercut to ensure proper
operation of the commutator.
4. Measure:
S armature assembly resistances (commutator and insulation)
Out of specification Replace the starter
motor.
a. Measure the armature assembly resistances with the pocket tester.
Pocket tester
90890-03112
Armature assembly
Commutator resistance 1
0.012 0.022 Ω at 20_C
Insulation resistance 2
Above 1 MΩ at 20_C
b. If any resistance is out of specification, replace the starter motor.
8-24
STARTER MOTOR
ELEC
5. Measure:
brush length a
Out of specification Replace the brushes
as a set.
Min. brush length
3.5 mm
6. Measure:
brush spring force
Out of specification Replace the brush
springs as a set.
Brush spring force
7.16 9.52 N (7.16 9.52 gf)
7. Check:
gear teeth
Damage/wear Replace the gear.
8. Check:
bearing
oil seal
Damage/wear Replace the defective
part(-s).
EB803701
ASSEMBLING THE STARTER MOTOR
1. Install:
brush seat 1
NOTE:
Align the tab a on the starter motor rear cover
with the slot b in the yoke.
2. Install:
starter motor yoke 1
O-rings 2 New
starter motor front cover 3
starter motor rear cover 4
bolts
5 Nm (0.5 mkg)
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
rear covers.
8-25
ELEC
CHARGING SYSTEM
EB804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
3
4
5
6
8-26
Rectifier/ regulator
AC magneto
Battery
Main fuse
CHARGING SYSTEM
EB804010
ELEC
EB802401
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
The battery is not being charged.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil assembly resistance
5. wiring
(of the entire charging system)
Open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) rider seat
2) fuel tank
S Troubleshoot with the following special
tool(-s).
NO
S Clean the battery
terminals.
S Recharge or
replace the battery.
EB804400
3. Charging voltage
Engine tachometer
90793-80009
Pocket tester
90890-03112
S Connect the engine tachometer to the spark
plug lead of cylinder #1.
S Connect the pocket tester (DC 20 V) to the
battery as shown.
Tester positive probe battery positive terminal
Tester negative probe battery negative terminal
EB802400
1. Main fuse
S Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Is the main fuse OK?
YES
S Start the engine and let it run at approximately 5,000 r/min.
S Measure the charging voltage.
NO
Replace the fuse.
Charging voltage
14 V at 5,000 r/min
8-27
CHARGING SYSTEM
ELEC
EB804404
5. Wiring
NOTE:
Make sure that the battery is fully charged.
S Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
S Is the charging system’s wiring properly connected and without defects?
S Is the charging voltage within specification?
NO
YES
NO
The charging circuit
is OK.
Properly connect or
repair the charging
system’s wiring.
EB804401
4. Stator coil assembly resistances
S Remove the generator cover.
S Connect the pocket tester (Ω 1) to the stator coil assembly coupler as shown.
Tester positive probe white 1
Tester negative probe white 2
Tester positive probe white 1
Tester negative probe white 3
S Measure the stator coil assembly resistances.
Stator coil resistance
0.27X 0.33 Ω at 20_C
S Is the stator coil assembly OK?
YES
NO
Replace the stator
coil assembly.
8-28
YES
Replace the rectifier/
regulator.
LIGHTING SYSTEM
ELEC
EB805000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
1
5
6
30
32
34
35
45
Main switch
Battery
Main fuse
High beam indicator light
Illumination light
Pass switch
Dimmer switch
Headlight
8-29
46
47
48
49
53
54
62
Auxiliary light
Headlight relay (Hi)
Headlight relay (LO)
Tail / brake light
Headlight fuse
Signaling system fuse
Light switch
LIGHTING SYSTEM
EB805010
ELEC
EB802401
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
Any of the following fail to light: headlight, high beam indicator light, taillight,
auxiliary light or meter light.
Open-circuit voltage
12.8 V or more at 20_C
Check:
1. main, signaling system, and headlight fuses
2. battery
3. main switch
4. lights switch
5. dimmer switch
6. pass switch
7. wiring
(of the entire charging system)
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or
replace the battery.
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) seats
2) fuel tank
3) air filter case
4) front cowling inner panels
5) front cowling
6) rear cowling
S Troubleshoot with the following special
tool(-s).
EB802411
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES
NO
Replace the main
switch.
Pocket tester
90890-03112
EB805400
EB802400
4. Lights switch (for Europe)
1. Main, signaling system, and headlight
fuses
S Check the lights switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the lights switch OK?
S Check the main, signaling system, and
headlight fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main, signaling system, and headlight fuses OK?
YES
YES
NO
The lights switch is
faulty. Replace the
right handlebar
switch.
NO
Replace the fuse(-s).
8-30
LIGHTING SYSTEM
EB805401
ELEC
EB805410
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
5. Dimmer switch
Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the dimmer switch OK?
YES
1. Headlight bulb and socket
Check the headlight bulb and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the headlight bulb and socket OK?
NO
The dimmer switch is
faulty. Replace the
left handlebar switch.
YES
Replace the headlight bulb, socket or
both.
EB805403
6. Pass switch
Check the pass switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the pass switch OK?
YES
NO
2. High beam indicator light LED
NO
Check the LED of the high beam indicator
light.
Refer to “CHECKING THE LEDs”.
Is the high beam indicator light LED OK?
The pass switch is
faulty. Replace the
left handlebar switch.
YES
NO
EB805404
7. Wiring
Replace the meter
assembly.
Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the lighting system’s wiring properly connected and without defects?
3. Voltage
YES
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING
THE
LIGHTING
SYSTEM”.
NO
Connect the pocket tester (DC 20 V) to the
headlight and high beam indicator light couplers as shown.
Properly connect or
repair the lighting
system’s wiring.
A When the dimmer switch is set to “
B When the dimmer switch is set to “
Headlight coupler (wire harness side)
8-31
”
”
LIGHTING SYSTEM
ELEC
Headlight
Tester positive probe yellow 1 or green 2
Tester negative probe black 3
High beam indicator light
Tester positive probe yellow 1
Tester negative probe black/blue 4
Meter assembly coupler (wire harness side)
Does the headlight relay have continuity between yellow (green) and red/yellow?
YES
This circuit is OK.
Set the main switch to “ON”.
Set the light switch to “
”.
Set the dimmer switch to “
” or “
”.
Measure the voltage (12 V) of yellow (green)
2 on the headlight coupler (headlight side).
Is the voltage within specification?
Replace the headlight relay.
EB805411
2. Illumination fails to come on.
1. Meter light bulb and socket.
Check the meter light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the meter light bulb and socket OK?
NO
YES
NO
The wiring circuit
from the main switch
to the headlight coupler is faulty and must
be repaired.
YES
NO
Replace the meter
light bulb, socket or
both.
4. Headlight relay (Hi or LO)
2. Voltage
Disconnect the headlight relay from the coupler.
Connect the pocket tester (Ω 1) and battery (12 V) to the headlight relay terminals as
shown.
Connect the pocket tester (20 V) to the meter
assembly coupler (wire harness side) as
shown.
Tester positive probe blue 1
Tester negative probe black/blue 2
Battery positive terminal white/yellow
(white/green) 1
Battery negative terminal black 2
Tester positive probe yellow (green) 4
Tester negative probe red/yellow 3
8-32
LIGHTING SYSTEM
Set the main switch to “ON”.
Set the light switch to “
” or “
”.
Measure the voltage (12 V) of blue 1 on the
meter assembly coupler (wire harness side).
Is the voltage within specification?
YES
This circuit is OK.
ELEC
Set the main switch to “ON”.
Set the light switch to “
” or “
”.
Measure the voltage (12 V) of blue/red 1 on
the tail/brake light coupler (wire harness
side).
Is the voltage within specification?
NO
YES
This circuit is OK.
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be repaired.
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
EB805412
EB805413
3. A tail/brake light fails to come on.
4. The auxiliary light fails to come on.
(for Europe)
1. Tail/brake light bulb and socket
1. Auxiliary light bulb and socket
Check the tail/brake light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the tail/brake light bulb and socket OK?
YES
Check the auxiliary light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the auxiliary light bulb and socket OK?
NO
YES
Replace the tail/
brake light bulb, socket or both.
NO
Replace the auxiliary
light bulb, socket or
both.
2. Voltage
2. Voltage
Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side) as
shown.
Connect the pocket tester (DC 20 V) to the
auxiliary light couplers (wire harness side) as
shown.
Tester positive probe blue/red 1
Tester negative probe black 2
Tester positive probe blue/red 1
Tester negative probe black 2
8-33
LIGHTING SYSTEM
Set the main switch to “ON”.
Set the light switch to “
” or “
”.
Measure the voltage (12 V) of blue/red 1 on
the auxiliary light couplers (wire harness
side).
Is the voltage within specification?
YES
This circuit is OK.
NO
The wiring circuit
from the main switch
to the auxiliary light
connectors is faulty
and must be repaired.
8-34
ELEC
SIGNALING SYSTEM
EB806000
SIGNALING SYSTEM
CIRCUIT DIAGRAM
8-35
ELEC
SIGNALING SYSTEM
1
5
6
9
12
21
22
25
26
27
28
29
31
36
37
39
40
41
42
43
44
49
54
57
58
59
61
Main switch
Battery
Main fuse
Starting circuit cutoff relay
Fuel sender
Neutral switch
Speed sensor
Fuel level indicator light
Oil level / coolant temperature
warning light
Neutral indicator light
Tachometer
Combination meter
Turn signal indicator light
Horn switch
Horn
Turn signal switch
Flasher relay
Front turn signal light (L)
Front turn signal light (R)
Rear turn signal light (L)
Rear turn signal light (R)
Tail / brake light
Signaling system fuse
Oil level relay
Oil level switch
Rear brake light switch
Front brake light switch
8-36
ELEC
SIGNALING SYSTEM
EB806010
ELEC
EB802401
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
chapter 3.
S Any of the following fail to light: turn signal light, brake light or an indicator light.
S The horn fails to sound.
Open-circuit voltage
12.8 V or more at 20_C
Check:
1. main and signaling system fuses
2. battery
3. main switch
4. wiring
(of the entire signaling system)
S Is the battery OK?
YES
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) seats
2) fuel tank
3) air filter case
4) front cowling inner panels
5) bottom cowling
6) side cowling inner panels
7) side cowlings
8) windshield
9) rear cowling
S Troubleshoot with the following special tool
(-s).
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EB802411
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES
NO
Replace
switch.
Pocket tester
90890-03112
the
main
EB806400
EB802400
1. Main and signaling system fuses
4. Wiring
S Check the main and signaling system fuses
for continuity.
Refer to “CHECKING AND CHARGING
THE FUSES” in chapter 3.
S Are the main and signaling system fuses
OK?
S Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the signaling system’s wiring properly connected and without defects?
YES
YES
NO
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING
THE
SIGNALING
SYSTEM”.
Replace the fuse(-s).
8-37
NO
Properly connect or
repair the signaling
system’s wiring.
SIGNALING SYSTEM
ELEC
EB806410
3. Horn
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
Disconnect the black connector at the horn
terminal.
Connect a jumper lead 1 to the horn terminal
and ground the jumper lead.
Set the main switch to “ON”.
Push the horn switch.
Does the horn sound?
1. Horn switch
Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the horn switch OK?
YES
NO
Replace the left handlebar switch.
2. Voltage
Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
NO
Tester positive probe pink 1
Tester negative probe ground
YES
The horn is OK.
4. Voltage
Connect the pocket tester (DC 20 V) to the
horn connector at the black terminal as
shown.
Tester positive probe black 1
Tester negative probe ground
Set the main switch to “ON”.
Push the horn switch.
Measure the voltage (12 V) of Pink at the horn
terminal.
Is the voltage within specification?
YES
NO
The wiring circuit
from the main switch
to the horn connector
is faulty and must be
repaired.
Set the main switch to “ON”.
Measure the voltage (12 V) of black 1 at the
horn terminal.
Is the voltage within specification?
YES
Repair or replace the
horn.
8-38
NO
Replace the horn.
SIGNALING SYSTEM
EB806411
Set the main switch to “ON”.
Pull in the brake lever or push down on the
brake pedal.
Measure the voltage (12 V) of yellow at the
tail/brake light coupler (wire harness side).
Is the voltage within specification?
2. A tail/brake light fails to come on.
1. Tail/brake light bulb and socket
Check the tail/brake light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the tail/brake light bulb and socket OK?
YES
ELEC
YES
This circuit is OK.
NO
Replace the tail/
brake light bulb, socket or both.
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
2. Brake light switches
Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the brake light switch OK?
YES
EB806413
3. A turn signal light, turn signal indicator light
or both fail to blink.
NO
1. Turn signal light bulb and socket
Check the turn signal light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the turn signal light bulb and socket OK?
Replace the brake
light switch.
3. Voltage
Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side) as
shown.
YES
NO
Replace the turn signal light bulb, socket
or both.
Tester positive probe yellow 1
Tester negative probe black 2
2. Turn signal indicator light LED
Check the LED of the turn signal indicator
light.
Refer to “CHECKING THE LEDs”.
Is the turn signal indicator light LED OK?
YES
NO
Replace the meter
assembly.
8-39
SIGNALING SYSTEM
Tester positive probe brown/white 1
Tester negative probe ground
3. Turn signal switch
Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the turn signal switch OK?
YES
ELEC
NO
Replace the left handlebar switch.
4. Voltage
Connect the pocket tester (DC 20 V) to the
relay coupler (wire harness side) as shown.
Set the main switch to “ON”.
Set the turn signal switch to “
” or “
”.
Measure the voltage (12 V) or brown/white at
the turn signal relay coupler (wire harness
side).
Is the voltage within specification?
Tester positive probe brown 1
Tester negative probe ground
YES
NO
The turn signal relay
is faulty and must be
replaced.
6. Voltage
Connect the pocket tester (DC 20 V) to the
turn signal light connectors or the meter assembly coupler (wire harness side) as
shown.
Set the main switch to “ON”.
Measure the voltage (12 V) of brown 1 at the
turn signal relay coupler (wire harness side).
Is the voltage within specification?
YES
A Turn signal light
B Turn signal indicator light
NO
Left turn signal light
Tester positive probe chocolate 1
Tester negative probe ground
Right turn signal light
Tester positive probe dark green 2
Tester negative probe ground
A
B
The wiring circuit
from the main switch
to the turn signal relay
coupler (turn signal
relay side) is faulty
and must be repaired.
5. Voltage
Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
8-40
SIGNALING SYSTEM
Set the main switch to “ON”.
Set the turn signal switch to “
” or “
”.
Measure the voltage (12 V) of chocolate 1 or
dark green 2 at the turn signal light connector (wire harness side).
Is the voltage within specification?
YES
This circuit is OK.
ELEC
3. Voltage
Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
Tester positive probe brown 1
Tester negative probe sky blue 2
NO
The wiring circuit
from the turn signal
switch to the turn signal light connector is
faulty and must be repaired.
EB806414
4. The neutral indicator light fails to come on.
Set the main switch to “ON”.
Measure the voltage (12 V) of brown 1 and
sky blue 2 at the meter assembly coupler.
Is the voltage within specification?
1. Neutral indicator light LED
Check the LED of the neutral indicator light.
Refer to “CHECKING THE LEDs”.
Is the neutral indicator light LED OK?
YES
YES
NO
This circuit is OK.
Replace the meter
assembly.
NO
The wiring circuit
from the main switch
to the meter light bulb
coupler is faulty and
must be repaired.
EB806416
2. Neutral switch
5. The oil level warning light fails to come on.
Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the neutral switch OK?
1. Oil level warning light LED
YES
Check the LED of the oil level warning light.
Refer to “CHECKING THE LEDs”.
Is the oil level warning light LED OK?
NO
YES
Replace the neutral
switch.
NO
Replace the meter
assembly.
8-41
SIGNALING SYSTEM
ELEC
2. Oil level switch
4. Voltage
Drain the engine oil and remove the oil level
switch from the oil pan.
Check the oil level switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the oil level switch OK?
Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
YES
Tester positive probe brown 1
Tester negative probe red/blue 2
NO
Replace the oil level
switch.
3. Oil level relay
Disconnect the oil level relay from the coupler.
Connect the pocket tester (Ω 1) and battery (12 V) to the oil level relay terminals as
shown.
Set the main switch to “ON”.
Measure the voltage (12 V) of brown 1 and
red/blue at the meter assembly coupler.
Is the voltage within specification?
Battery positive terminal brown 1
Battery negative terminal white 2
YES
Tester positive probe red/blue 3
Tester negative probe black 4
This circuit is OK.
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be repaired.
EB806417
6. The fuel level indicator light fails to come
on.
1. Fuel level indicator light LED
Does the oil level relay have continuity between red/blue and black?
YES
Check the LED of the fuel level indicator light.
Refer to “CHECKING THE LEDs”.
Is the fuel level indicator light LED OK?
NO
YES
Replace the oil level
relay.
NO
Replace the meter
assembly.
8-42
SIGNALING SYSTEM
ELEC
Set the main switch to “ON”.
Measure the voltage (12 V).
Is the voltage within specification?
2. Fuel sender
Disconnect the fuel sender coupler from the
wire harness.
Drain the fuel from the fuel tank and remove
the fuel sender from the fuel tank.
Check the fuel sender for continuity.
YES
This circuit OK.
Tester positive probe green 1
Tester negative probe black 2
NO
The wiring circuit from
the main switch to the
meter assembly coupler is faulty and must
be repaired.
EAS00805
7.The clock fails to come on.
1. Voltage
Connect the pocket tester (20 V DC) to the
clock coupler (clock side) as shown.
Tester positive probe green/yellow 1
Tester negative probe ground
Is the fuel sender OK?
YES
NO
Replace
sender.
the
fuel
3. Voltage
Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as
shown.
Set the main switch to “ON”.
Measure the voltage (12 V).
Is the voltage within specification?
Tester positive probe green/white 1
Tester negative probe black/blue 2
YES
NO
The wiring circuit from the main
switch to the clock coupler
(clock side) is faulty and must be
repaired.
2. Clock
Check that the clock is operating properly.
When setting the clock after its power source
has been disconnected (e.g., when the battery
is removed), first set the clock to 1:00 AM and
then to the correct time.
Is the clock operating properly?
YES
8-43
This circuit is OK.
NO
Replace the clock.
SIGNALING SYSTEM
ELEC
EAS00806
The speedometer fails to come on.
1. Speedometer bulb socket
Check the speedometer bulb socket for continuity.
Is the speedometer bulb socket OK?
YES
NO
Replace the speedometer bulb
socket.
Set the main switch to “ON”.
Measure the voltage (12 V) of blue 1 on the
speedometer bulb socket coupler (wire harness side).
Is the voltage within specification?
2. Voltage
Connect the pocket tester (20 V DC) to the
speedometer coupler (wire harness side) as
shown.
YES
Battery positive lead green/yellow 1
Battery negative lead black/blue 2
Battery positive lead red 3
NO
The wiring circuit from the main
switch to the speedometer bulb
socket coupler (wire harness
side) is faulty, repair it.
4. Speedometer sensor
Connect the pocket tester (20 V DC) to the
speedometer coupler (wire harness side) as
shown.
Tester positive probe blue/yellow 1
Tester negative probe black/blue 2
NOTE:
First, connect the battery to the green/yellow
1 and black/blue 2 coupler terminals, then
connect the battery positive lead to the
red/green 3 terminal.
When connecting the battery, check whether
the startup display 3 appears first and then after approximately three seconds the normal
display appears 4.
Does the startup display appear first and then
after approximately three seconds the normal
display appears?
YES
Set the main switch to “ON”.
Elevate the rear wheel and slowly rotate it.
Measure the voltage (5 V) of blue/yellow and
black/blue. With each full rotation of the rear
wheel, the voltage reading should cycle from
0 V to 5 V to 0 V to 5 V.
Does the voltage reading cycle correctly?
NO
Replace the speedometer.
3. Voltage
Connect the pocket tester (20 V DC) to the
speedometer bulb socket coupler (wire harness side) as shown.
YES
This circuit is OK.
Tester positive probe blue 1
Tester negative probe blue/black 2
8-44
NO
Replace the speedometer sensor.
COOLING SYSTEM
EB807000
COOLING SYSTEM
CIRCUIT DIAGRAM
1
5
6
23
26
29
50
51
52
54
Main switch
Battery
Main fuse
Thermo unit
Oil level / coolant temperature
warning light
Combination meter
Radiator fan motor
Thermo switch
Radiator fan motor fuse
Signaling system fuse
8-45
ELEC
COOLING SYSTEM
ELEC
EB807010
Open-circuit voltage
12.8 V or more at 20_C
TROUBLESHOOTING
S The radiator fan motor fails to turn.
S The coolant temperature display and/or
warning light fails to indicate when the
engine is warm.
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
Check:
1. main, signal system, and radiator fan motor
fuses
2. battery
3. main switch
4. radiator fan motor
5. thermo switch
6. thermo unit
7. wiring
(the entire cooling system)
EB802411
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) rider seat
2) bottom cowling
3) front cowling inner panels
4) side cowling inner panels
5) side cowlings
6) windshield
S Troubleshoot with the following special tool
(-s).
YES
NO
Replace
switch.
the
main
EB807400
4. Radiator fan motor (test 1)
S Disconnect the radiator fan motor coupler
from the wire harness.
S Connect the battery (12 V) as shown.
Battery positive lead blue 1
Battery negative lead black 2
Pocket tester
90890-03112
EB802400
1. Main, signal system and radiator fan
motor fuses
S Check the main, signal system, and radiator
fan motor fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main, signal system, and radiator fan
motor fuses OK?
YES
S Does the radiator fan motor turn?
NO
YES
NO
Replace the fuse(-s).
The radiator fan motor is faulty and must
be replaced.
EB802401
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
8-46
COOLING SYSTEM
EB807400
5. Radiator fan motor (test 2)
S Disconnect the thermo switch coupler.
S Set the main switch to “ON”.
S Connect the brown 1 and blue 2 terminals
with a jumper lead 3 as shown.
ELEC
Test
step
Coolant temperature
Thermo switch
Continuity
*1*
*2*
*3*
*4*
0 X 105 ± 3_C
NO
More than 105 ± 3_C
YES
105 ± 3_C to 100 ± 3_C
YES
Less than 100 ± 3_C
NO
Test steps 1 & 2: Heating phase
Test steps 3* & 4*: Cooling phase
S Does the radiator fan motor turn?
YES
NO
The wiring circuit
from the main switch
to the radiator fan motor coupler is faulty
and must be repaired.
6. Thermo switch
S Remove the thermo switch from the radiator.
S Connect the pocket tester (Ω 1) to the thermo switch 1 as shown.
S Immerse the thermo switch in a container
filled with coolant 2 .
NOTE:
Make sure that the thermo switch terminals
do not get wet.
WARNING
S Handle the thermo switch with special
care.
S Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
S Place a thermometer 3 in the coolant.
S Slowly heat the coolant, then let it cool to the
specified temperature as indicated in the
table.
S Check the thermo switch for continuity at the
temperatures indicated in the table.
Thermo switch
28 Nm (2.8 mSkg)
Three bond sealock 10
A The thermo switch circuit is open and the radiator fan is off.
B The thermo switch circuit is closed and the
radiator fan is on.
8-47
COOLING SYSTEM
100 ± 3 _C
ELEC
105 ± 3 _C
S Does the thermo switch operate properly as
described above?
YES
NO
Replace the thermo
switch.
7. Thermo unit
S Remove the temperature sender from the
cylinder head.
S Connect the pocket tester (Ω
10) to the
thermo unit 1 as shown.
S Immerse the thermo unit in a container filled
with coolant 2 .
S Place a thermometer 3 in the coolant.
S Slowly heat the water, then let it cool down to
the specified temperature.
S Check the thermo unit for continuity at the
temperatures indicated below.
WARNING
Handle the temperature sender with special care.
Never subject the temperature sender to
strong shocks. If the temperature sender
is dropped, replace it.
Temperature sender
15 Nm (1.5 mSkg)
Three bond sealock 10
Thermo unit resistance
50.6 X 64.2 Ω at 80_C
17.3 X 16.1 Ω at 120_C
YES
NO
Replace the temperature sender.
EB807403
8. Wiring
S Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the cooling system’s wiring properly connected and without defects?
YES
Replace the combination meter.
8-48
NO
Properly connect or
repair the cooling
system’s wiring.
FUEL PUMP SYSTEM
ELEC
EB808000
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
1
5
6
9
10
14
54
56
63
8-49
Main switch
Battery
Main fuse
Starting circuit cutoff relay
Fuel pump
CDI unit
Signaling system fuse
Ignition fuse
Engine stop switch
FUEL PUMP SYSTEM
EB808010
FUEL PUMP CIRCUIT OPERATION
The CDI unit includes the control unit for the fuel pump.
1
2
3
4
5
6
7
8
Battery
Main fuse
Main switch
Ignition fuse
Engine stop switch
CDI unit
Starting circuit cutoff relay
Fuel pump
8-50
ELEC
FUEL PUMP SYSTEM
EB808020
ELEC
EB802401
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
The fuel pump fails to operate.
Check:
1. main and ignition fuses
2. battery
3. main switch
4. engine stop switch
5. starting circuit cutoff relay
6. fuel pump
7. wiring
(the entire fuel pump system)
Open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
S Clean the battery
terminals.
S Recharge or replace the battery.
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) rider seat
2) fuel tank
3) air filter case
4) front cowling inner panel (left)
S Troubleshoot with the following special
tool(-s).
EB802411
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
Pocket tester
90890-03112
YES
NO
Replace
switch.
EB802400
1. Main and ignition fuses
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main and ignition fuses OK?
YES
NO
the
main
EB802412
4. Engine stop switch
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
NO
YES
NO
Replace the fuse(-s).
Replace the right
handlebar switch.
8-51
FUEL PUMP SYSTEM
ELEC
S Measure the fuel pump resistance.
5. Starting circuit cutoff relay
S Disconnect the relay from the coupler.
S Connect the pocket tester (Ω
1) and battery (12 V) to the relay terminals as shown.
Fuel pump resistance
4 X 30 Ω at 20_C
S Is the fuel pump OK?
Battery positive terminal red 1
Battery negative terminal blue/red 2
YES
Tester positive probe red 1
Tester negative probe blue/black 3
NO
Replace
pump.
the
fuel
EB808401
7. Wiring
S Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the fuel pump system’s wiring properly
connected and without defects?
YES
S Does the fuel pump relay have continuity between red/black and blue/black?
YES
Replace the CDI unit.
NO
Replace the starting
circuit cutoff relay.
EB808400
6. Fuel pump resistance
S Disconnect the fuel pump coupler from the
wire harness.
S Connect the pocket tester (Ω 1) to the fuel
pump coupler (fuel pump side) as shown.
Tester positive probe blue/black 1
Tester negative probe black 2
8-52
NO
Properly connect or
repair the fuel pump
system’s wiring.
FUEL PUMP SYSTEM
ELEC
EB808410
CHECKING THE FUEL PUMP
WARNING
Gasoline is extremely flammable and under
certain circumstances there can be a danger of an explosion or fire. Be extremely
careful and note the following points:
Stop the engine before refuelling.
Do not smoke and keep away from open
flames, sparks or any other source of fire.
If you do accidentally spill gasoline, wipe it
up immediately with dry rags.
If gasoline touches the engine when it is
hot, a fire may occur. Therefore, make sure
that the engine is completely cool before
performing the following test.
1. Check:
fuel pump operation
a. Fill the fuel tank.
b. Put the end of the fuel hose into an open container.
c. Connect the battery (12 V) to the fuel pump
coupler as shown.
Battery positive lead blue/black 1
Battery negative lead black 2
d. If fuel flows out of the fuel hose, the fuel
pump is OK. If fuel does not flow, replace the
fuel pump.
8-53
SELF-DIAGNOSIS
ELEC
EB812000
SELF-DIAGNOSIS
The YZF-R6 features a self-diagnosing system for the following circuit(-s):
throttle position sensor
fuel level indicator light
If any of these circuits are defective, their respective condition codes will be displayed on the tachometer when the main switch is set to “ON” (irrespective of whether the engine is running or not)
Circuit
Defect(-s)
System response
Condition code
Throttle position sensor
Disconnected
Short-circuit
Locked
The ignitor unit stays set to the
wide-open throttle ignition timing.
The motorcycle can be ridden.
The tachometer displays the
condition code.
3,000 r/min
Fuel level indicator light
Improper connection
The tachometer displays the
condition code.
8,000 r/min
Tachometer display sequence
Revolution
( 103 r / min)
1 0 r / min ... 3 seconds
2 Condition code ... 2.5 seconds
3 Engine speed ... 3 seconds
Tachometer display
Engine speed
Time (seconds)
When more than one item is being monitored, the tachometer needle displays the condition codes in
ascending order, cycling through the sequence repeatedly.
If the engine is stopped, the engine speed 3 is 0 r/min.
8-54
ELEC
SELF-DIAGNOSIS
EB812010
1. Wire harness
TROUBLESHOOTING
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
The tachometer starts to display the selfdiagnosis sequence.
Check:
1. throttle position sensor
2. fuel level indicator light
YES
NO
Repair or replace the
wire harness.
NOTE:
Before troubleshooting, remove the following
part(-s):
1) rider seat
2) fuel tank
3) air filter case
4) right side cowling inner panel
5) right side cowling
Troubleshoot with the following special
tool(-s).
EB812401
2. Throttle position sensor
Check the throttle position sensor for continuity.
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR” in
chapter 6.
Is the throttle position sensor OK?
Pocket tester
90890-03112
YES
Replace the CDI unit.
EB812020
1. Throttle position sensor
CIRCUIT DIAGRAM
13 Throttle position sensor
14 CDI unit
8-55
NO
Replace the throttle
position sensor.
SELF-DIAGNOSIS
EB812040
ELEC
EB812403
2. Fuel level indicator light
CIRCUIT DIAGRAM
1. Fuel level indicator light LED
Check the LED of the fuel level indicator light.
Refer to “CHECKING THE LEDs”.
Is the fuel level indicator light LED OK?
YES
NO
Repair the fuel level
indicator light LED.
EB812404
2. Fuel sender
Disconnect the fuel sender coupler from the
wire harness.
Connect the pocket tester (W 1) to the fuel
sender coupler as shown.
Tester positive probe green 1
Tester negative probe black 2
Check the fuel sender for continuity.
Is the fuel sender OK?
YES
NO
Replace
sender.
12
14
25
29
Fuel sender
CDI unit
Fuel level indicator light
Combination meter
8-56
the
fuel
SELF-DIAGNOSIS
EB812405
3. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
Replace the CDI unit.
NO
Replace or replace
the wire harness.
8-57
ELEC
ELEC
TRBL
SHTG
9
TRBL
SHTG
CHAPTER 9.
TROUBLESHOOTING
STARTING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-1
9-1
INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
9-2
9-2
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 9-2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFTING IS DIFFICULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUMPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
9-2
9-2
9-2
FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3
9-3
9-3
9-3
9-3
9-3
OVERCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FAULTY FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
LEAKING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
TRBL
SHTG
UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FAULTY LIGHTING AND SIGNALING SYSTEMS . . . . . . . . . . . . . . . . . .
HEADLIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAIL/BRAKE LIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . .
TAIL/BRAKE LIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL REMAINS LIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-5
STARTING PROBLEMS
TRBL
SHTG
EB900000
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure is this manual for
checks, adjustments, and replacement of parts.
STARTING PROBLEMS
FUEL SYSTEM
Fuel tank
Empty fuel tank
Clogged fuel filter
Clogged fuel tank breather hose
Deteriorated or contaminated fuel
Fuel pump
Faulty fuel pump
Faulty fuel pump relay
Fuel cock
Clogged or damaged fuel hose
Carburetors
Deteriorated or contaminated fuel
Clogged pilot jet
Clogged pilot air passage
Sucked-in air
Damaged float
Worn needle valve
Incorrectly installed needle valve seat
Incorrect fuel level
Incorrectly installed pilot jet
Clogged starter jet
Faulty starter plunger
Incorrectly adjusted starter cable
ENGINE
Cylinders and cylinder head(-s)
Loose spark plug
Loose cylinder head
Damaged cylinder head gasket
Worn or damaged cylinder
Incorrect valve clearance
Incorrectly sealed valve
Incorrect valve-to-valve-seat contact
Incorrect valve timing
Faulty valve spring
Seized valve
Pistons and piston rings
Incorrectly installed piston ring
Damaged, worn or fatigued piston ring
Seized piston ring
Seized or damaged piston
Air filter
Incorrectly installed air filter
Clogged air filter element
Crankcase and crankshaft
Incorrectly assembled crankcase
Seized crankshaft
ELECTRICAL SYSTEMS
Battery
Faulty battery
Discharged battery
Fuses
Blown, damaged or incorrect fuse
Incorrectly installed fuse
Spark plugs
Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
Faulty spark plug cap
Ignition coils
Damaged ignition coil
Broken or shorted primary or secondary coils
Ignition system
Faulty CDI unit
Faulty pickup coil
Switches and wiring
Faulty main switch
Faulty engine stop switch
Broken or shorted wiring
Faulty neutral switch
Faulty start switch
Faulty sidestand switch
Faulty clutch switch
Incorrectly grounded circuit
Loose connections
Starting system
Faulty starter motor
Faulty starter relay
Faulty starting circuit cutoff relay
Faulty starter clutch
9-1
INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-ANDHIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING
TRBL
SHTG
EB901000
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
Faulty battery
Discharged battery
Spark plugs
Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
Faulty spark plug cap
Ignition coils
Broken or shorted primary or secondary coils
Faulty spark plug lead
Damaged ignition coil
Ignition system
Faulty ignition unit
Faulty pickup coil
ENGINE
Cylinders and cylinder head
Incorrect valve clearance
Damaged valve train components
Air filter
Clogged air filter element
FUEL SYSTEM
Carburetors
Faulty starter plunger
Loose or clogged pilot jet
Loose or clogged pilot air jet
Damaged or loose carburetor joint
Incorrectly synchronized carburetors
Incorrectly adjusted engine idling speed
(throttle stop screw)
Incorrect throttle cable free play
Flooded carburetor
EB902000
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING PROBLEMS”.
ENGINE
Air filter
Clogged air filter element
Air intake system
Clogged air ducts
FUEL SYSTEM
Carburetors
Faulty diaphragm
Incorrect fuel level
Loose or clogged main jet
Fuel pump
Faulty fuel pump
EB903000
FAULTY GEAR SHIFTING
JUMPS OUT OF GEAR
Shift shaft
Incorrect shift pedal position
Incorrectly returned stopper lever
Shift forks
Worn shift fork
Shift drum
Incorrect axial play
Worn shift drum groove
Transmission
Worn gear dog
SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
Incorrectly adjusted shift rod
Bent shift shaft
Shift drum and shift forks
Foreign object in a shift drum groove
Seized shift fork
Bent shift fork guide bar
Transmission
Seized transmission gear
Foreign object between transmission gears
Incorrectly assembled transmission
9-2
FAULTY CLUTCH/OVERHEATING/OVERCOOLING
TRBL
SHTG
EB904000
FAULTY CLUTCH
CLUTCH DRAGS
Clutch
Unevenly tensioned clutch spring plate
Warped pressure plate
Bent clutch plate
Swollen friction plate
Bent clutch pull rod
Damaged clutch boss
Burnt primary driven gear bushing
Match marks not aligned
Engine oil
Incorrect oil level
Incorrect oil viscosity (high)
Deteriorated oil
CLUTCH SLIPS
Clutch
Incorrectly assembled clutch
Incorrectly adjusted clutch cable
Loose or fatigued clutch spring
Worn friction plate
Worn clutch plate
Engine oil
Incorrect oil level
Incorrect oil viscosity (low)
Deteriorated oil
EB905001
OVERHEATING
FUEL SYSTEM
Carburetors
Incorrect main jet setting
Incorrect fuel level
Damaged or loose carburetor joint
Air filter
Clogged air filter element
ENGINE
Clogged coolant passages
Cylinder head(-s) and piston(-s)
Heavy carbon buildup
Engine oil
Incorrect oil level
Incorrect oil viscosity
Inferior oil quality
CHASSIS
Brakes
Dragging brake
COOLING SYSTEM
Coolant
Low coolant level
Radiator
Damaged or leaking radiator
Faulty radiator cap
Bent or damaged radiator fin
Water pump
Damaged or faulty water pump
Thermostat
Thermostat stays closed
Oil cooler
Clogged or damaged oil cooler
Hoses and pipes
Damaged hose
Incorrectly connected hose
Damaged pipe
Incorrectly connected pipe
ELECTRICAL SYSTEMS
Spark plugs
Incorrect spark plug gap
Incorrect spark plug heat range
Ignition system
Faulty CDI unit
EB906000
OVERCOOLING
COOLING SYSTEM
Thermostat
Thermostat stays open
9-3
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK
LEGS/UNSTABLE HANDLING
TRBL
SHTG
EB907000
POOR BRAKING PERFORMANCE
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level
Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
Faulty brake caliper piston seal
EB908001
FAULTY FRONT FORK LEGS
MALFUNCTION
Bent or damaged inner tube
Bent or damaged outer tube
Damaged fork spring
Worn or damaged outer tube busing
Bent or damaged damper rod
Incorrect oil viscosity
Incorrect oil level
LEAKING OIL
Bent, damaged or rusty inner tube
Damaged outer tube
Incorrectly installed oil seal
Damaged oil seal lip
Incorrect oil level (high)
Loose damper rod assembly bolt
Damaged damper rod assembly bolt copper
washer
Damaged cap bolt O-ring
EB909001
UNSTABLE HANDLING
Swingarm
Worn bearing or bushing
Bent or damaged swingarm
Rear shock absorber assembly
Faulty rear shock absorber spring
Leaking oil or gas
Tires
Uneven tire pressures (front and rear)
Incorrect tire pressure
Uneven tire wear
Wheels
Incorrect wheel balance
Deformed cast wheel
Damaged wheel bearing
Bent or loose wheel axle
Excessive wheel runout
Frame
Bent frame
Damaged steering head pipe
Incorrectly installed bearing race
Handlebars
Bent or incorrectly installed right handlebar
Bent or incorrectly installed left handlebar
Steering head components
Incorrectly installed upper bracket
Incorrectly installed lower bracket
(incorrectly tightened ring nut)
Bent steering stem
Damaged ball bearing or bearing race
Front fork legs
Unevenoil levels (both front fork legs)
Unevenly tensioned fork spring (both front fork
legs)
Damaged fork spring
Bent or damaged inner tube
Bent or damaged outer tube
9-4
FAULTY LIGHTING AND SIGNALING SYSTEMS
TRBL
SHTG
EB910000
FAULTY LIGHTING AND SIGNALING SYSTEMS
TURN SIGNAL DOES NOT LIGHT
Faulty turn signal switch
Faulty turn signal relay
Burnt-out turn signal bulb
Incorrect connection
Damaged or faulty wire harness
Incorrectly grounded circuit
Faulty battery
Blown, damaged or incorrect fuse
HEADLIGHT DOES NOT LIGHT
Wrong headlight bulb
Too many electrical accessories
Hard charging
Incorrect connection
Incorrectly grounded circuit
Poor contacts (main or light switch)
Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT
Wrong headlight bulb
Faulty battery
Faulty rectifier/regulator
Incorrectly grounded circuit
Faulty main switch
Faulty light switch
Headlight bulb life expired
TURN SIGNAL BLINKS SLOWLY
Faulty flasher relay
Faulty main switch
Faulty turn signal switch
Wrong turn signal bulb
TURN SIGNAL REMAINS LIT
Faulty flasher relay
Burnt-out-turn signal bulb
TAIL/BRAKE LIGHT DOES NOT LIGHT
Wrong tail/brake light bulb
Too may electrical accessories
Incorrect connection
Burnt-out tail/brake light bulb
TURN SIGNAL BLINKS QUICKLY
Incorrect turn signal bulb
Faulty flasher relay
Burnt-out turn signal bulb
TAIL/BRAKE LIGHT BULB BURNT OUT
Wrong tail/brake light bulb
Faulty battery
Incorrectly adjusted rear brake light switch
Tail/brake light bulb life expired
HORN DOES NOT SOUND
Incorrectly adjusted horn
Damaged or faulty horn
Faulty main switch
Faulty horn switch
Faulty battery
Blown, damaged or incorrect fuse
Faulty wire harness
9-5
TRBL
SHTG
YZF-R6 ’99 WIRING DIAGRAM (for Europe)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
Main switch
Fuse (backup)
Rectifier / regulator
AC magneto
Battery
Fuse (main)
Starter relay
Starter motor
Starting circuit cutoff relay
Fuel pump
Sidestand switch
Fuel sender
Throttle position sensor
CDI unit
lgnition coil #1
lgnition coil #2
lgnition coil #3
lgnition coil #4
Spark plug
Pickup coil
Neutral switch
Speed sensor
Thermo unit
Meter assembly
Fuel level indicator light
Oil level / coolant temperature
warning light
Neutral indicator light
Tachometer
Combination meter
High beam indicator light
Turn signal indicator light
lllumination light
Handlebar switch (left)
Pass switch
Dimmer switch
Horn switch
Horn
Clutch switch
Turn signal switch
Flasher relay
Front turn signal light (L)
Front turn signal light (R)
Rear turn signal light (L)
Rear turn signal light (R)
Headlight
Auxiliary light
Headlight relay (Hi)
Headlight relay (Lo)
Tail / brake light
Radiator fan motor
Thermo switch
Fuse (radiator fan motor)
Fuse (headlight)
Fuse (signaling system)
Alarm
Fuse (ignition)
Oil level relay
Oil level switch
Rear brake light switch
Handlebar switch (right)
Front brake light switch
Light switch
Engine stop switch
Start switch
Diode 1
Diode 2
COLOR CODE
B .....
Br . . . .
Ch . . .
Dg . . .
G ....
Gy . . .
Black
Brown
Chocolate
Dark green
Green
Gray
L .....
O ....
P .....
R.....
Sb . . . .
W ....
Blue
Orange
Pink
Red
Sky blue
White
Y .....
B/L . . .
B/Y. . .
Br / B . .
Br / L . .
Br / R . .
Yellow
Black / Blue
Black / Yellow
Brown / Black
Brown / Blue
Brown / Red
Br / W . .
G/R . .
G/W . .
G / Y. . .
Gy / B . .
L/B . . .
Brown / White
Green / Red
Green / White
Green / Yellow
Gray / Black
Blue / Black
L/R . . .
L/W . .
L/Y . . .
O / B. . .
R / B. . .
R/L . . .
Blue / Red
Blue / White
Blue / Yellow
Orange / Black
Red / Black
Red / Blue
R/W . .
R / Y. . .
W/G . .
W/R . .
W/Y . .
Y/B. . .
Red / White
Red / Yellow
White / Green
White / Red
White / Yellow
Yellow / Blcak
YZF-R6 ’99 WIRING DIAGRAM (for AUS)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
47
48
49
50
51
52
53
54
56
57
58
59
60
61
63
64
65
66
Main switch
Fuse (backup)
Rectifier / regulator
AC magneto
Battery
Fuse (main)
Starter relay
Starter motor
Starting circuit cutoff relay
Fuel pump
Sidestand switch
Fuel sender
Throttle position sensor
CDI unit
lgnition coil #1
lgnition coil #2
lgnition coil #3
lgnition coil #4
Spark plug
Pickup coil
Neutral switch
Speed sensor
Thermo unit
Meter assembly
Fuel level indicator light
Oil level / coolant temperature
warning light
Neutral indicator light
Tachometer
Combination meter
High beam indicator light
Turn signal indicator light
lllumination light
Handlebar switch (left)
Pass switch
Dimmer switch
Horn switch
Horn
Clutch switch
Turn signal switch
Flasher relay
Front turn signal light (L)
Front turn signal light (R)
Rear turn signal light (L)
Rear turn signal light (R)
Headlight
Headlight relay (Hi)
Headlight relay (Lo)
Tail / brake light
Radiator fan motor
Thermo switch
Fuse (radiator fan motor)
Fuse (headlight)
Fuse (signaling system)
Fuse (ignition)
Oil level relay
Oil level switch
Rear brake light switch
Handlebar switch (right)
Front brake light switch
Engine stop switch
Start switch
Diode 1
Diode 2
COLOR CODE
B .....
Br . . . .
Ch . . .
Dg . . .
G ....
Gy . . .
Black
Brown
Chocolate
Dark green
Green
Gray
L .....
O ....
P .....
R.....
Sb . . . .
W ....
Blue
Orange
Pink
Red
Sky blue
White
Y .....
B/L . . .
B/Y. . .
Br / B . .
Br / L . .
Br / R . .
Yellow
Black / Blue
Black / Yellow
Brown / Black
Brown / Blue
Brown / Red
Br / W . .
G/R . .
G/W . .
G / Y. . .
Gy / B . .
L/B . . .
Brown / White
Green / Red
Green / White
Green / Yellow
Gray / Black
Blue / Black
L/R . . .
L/W . .
L/Y . . .
O / B. . .
R / B. . .
R/L . . .
Blue / Red
Blue / White
Blue / Yellow
Orange / Black
Red / Black
Red / Blue
R/W . .
R / Y. . .
W/G . .
W/R . .
W/Y . .
Y/B. . .
Red / White
Red / Yellow
White / Green
White / Red
White / Yellow
Yellow / Blcak